MAINTENANCE

and

OPERATION
of

AUTO-LITE
ELECTRICAL EQUIPMENT

PRICE $1.00

Issued by

The Electric Auto-Lite Company

Parts and Service Division
Toledo, Ohio, U.S.A.
PRINTED IN THE UNITED STATES OF AMERICA
 TABLE 'OF CONTENTS
Pag9 .'Page
DISTRIBUTORS . Relays and Regulators, ConI' d.·
Description and Function .. 8 VRB, VRD, VRE, VR~, VRJ, VRK, VRO, VRP,
Governor Control Data .................. . .... 21 VRR, VRS, VRT, VRU, VRV, VRW and' VRJ(
Numerical Index ................. .. ,.... 18 Regulators
Synchronizing ..... .. .................. 15 Car Test..
Tune-up Procedure ............. ,12 Description and Function ........... 46
Vacuum Advance Data .. ... 25 Maintenance Procedure ... ,......................... .48-.
Numerical Index ...................................... 65
GENERATORS ".1
Testing and ·Adjusting ........................ ' ... 53
Description pnd Function ............ 26 Test Specifications... ....... ....... ..... -.~; .68
Maintenance Procedure ................ 29
Numerical Index.. .. ............ .. VRA, VRC, VRG, VRH "nd ,VRY Regulators '
. ~~

Overhaul Procedure .... . .. 30 Car Test .................................... 47,

Test Specifications ..
IGNITION COILS ...
RELAYS AND REGULATORS
CB, CSA and RA Circuit Breakers
Description and Function, .... ..
Maintenance Procedure .......... .
Test Specifications
TC Regulators
Description and Function ........ , ....
Maintenance Procedure ..
Tasting and Adjusting .. .
Test Specifications ......................... .
............. 39 Descrip~ion an'd Function ..'............ : .... .:~;.;56>,. ,".
Maintenance Procedure ................... "'i;; '.' ~56.,-"
Numericallnde~ ........... ·.-... :......... , ............ ,.. t~.t'5",:,
Testing and Adjusting ..... " ................ :,: .... ~,,61,
Tesf Specifica~ions ....................... -;. ~ .68;
'''~
... 40
...40
STARTING MOTORS' ANDl;iWITCHES
41
Description and Function .............. ;;...
Maintenance Procedure .... .
..41 Motor Test Specifi~otic)'ns ...._.....
.. .... 42 Overhaul Proce~u're ...... .,;::.)' ..
". ":.:':'::''':<'~
.. ................ 44 Switch Tests and Spedficat.ions ... :·:·~: '~J'.;"'"
WINDSHIELD WIPERS " -,'I\'.

EW and' EWA Series: .. ........,. _.1:.::.

EWB and EWC Series
EWD and EWE Series
Test Specifications ... ,......................... ,..

Complete technical information on all Auto-lile equipm~nf'is included 'in the

Service Manual Binder which is in. the possession of every Auto-Lite Service, " ,."
Station. ,
Should additi~nal. information' b~l'equ.i;~d on any of the equipmerit~o,!ered
in this manual or l)n any Auto:htiLunit 'not covered in this:book It c9r1!je,
obtained f~om any Official A~t.,~l:ite SerVice 'Station, .".
-! .""'-.

THE
,
i.~TRIC
tl1?"'.'
AUTO-LITE COMPANY'
:. ••/" .
PARTS AND SERVICE Dlvrsl9N. "
, J;OLEp,O, .mI16, U.S.A. d • ::'
,,
•

...•". .,',
 AUTO-LITE RICAl EQUIPMENT

SERVICE TOOLS
In order to meet the demands for accurate re- The following list includes a ,few of the
sults automotive service men must be skilled in Service Tools that are available. Those included,
the art of measurement. This includes the use <;If are the tools which are required for aocu,dll,'"
the following essential service station tools. adjustment service.
1. Voltmeter 7. Vacuum Gauge
2. Ammeter 8. Compression Gauge
3. Ohmeter 9. Coil Tester
4. Timing Li9ht 10. Micrometers
5. Gap Gauges 11. Distributor Test Fixture
6. Feeler Gouges 12. Condenser Tester
Several of these units have been developed to
Auto-Lite specifications as fine precision instru-
ments while others may be obtained from several
,
dependable sources.
In handling electrical measuring instruments
it should be 'remembered that they are extremely
sensitive and delicately balanced. They should
not, therefore, be subjected to sudden shocks nor
should they be subjected to excessive vibration.
A sland such os illustrated in Figure 1 is. com-
paratively easy to make and will eliminate the
vibration they receive when placed on the car
ST -232APORTABLE EL.EC,.RXCT'S'l5;J;Ell{l
with the engine running.
,. (P.E.i.) ' " -

, This instrument (Figure ~) WCI$j~j

oped for the" use,: of. :'()ffiiri..d

"
Service Statiorisso
. .
that fh~Y.. ~

an instrument of the ne.:esspry a.'~,~~irp<~,"~~ii

and durability at I,ow cost,,'
Both voltm!lter and am!l1.~'~.r a.r,eohhl!l,;
horizontaT typet~ ob'';,;n'
sible scale so that inc:liecltil)ns, riiiii,,::)bjl:,
read accur~tely. " .,

2- -i X20 SETSCREWS . . rai~g,.s,:Jwlffal:

. The volt!l1eter has follr'
I" ANGLE IRON
are selectedbya rotaty:''''-'''''t
on the right hari~side .of ,
FIGURE 1
 AUTO-LITE 'ELECTRICAL
SERVICE TOOlS - Continued
0- 5 volt scale for testin~ hiSh resistances and
electrical devices operating at low volt-
ages.
0-10 volt scale for general use on 6 volt
circuits.
~-20 vqlt scale for general use on 12 volt
circuits.
0-50 volt scale for general use on 24 and 32
volt circuits.
For the 0-10 volt scale there are 100 divisions
so that each represents .1 volts. Accuracy of the
~oltmeter is held within 1% of all parts of the
, scale, except between 6 and 9 volts where it is
held to clr % accuracy. This is necessary as this
latter portion of the scale is the most commonly
: ,;lil5ed;,;jn testing 6 volt circuits.
·""[Ji"-<-('·';('" :~-"
The ammeter has two scales:
3-0-10 ampere scale for testing low current
draw.
15-0-50 ampere scale for general use in test-
ing automotive circuits.
Depressed zero scales are built into the instru-
, ment to avoid the necessity of changing the am-
- meter connections to obtain negative readings
s,uch as the amperes discharge required to open
circuit breakers.
The accuracy of the ammeter is held within 2%
of full scale deflection.
/>.. t ohm rheostat of 50 ampere capacity is
included in this instrument for use in setting volt-
age to test specifications.
There are four current carrying binding posts'
on the instrument: The 'first one on the right hand
side, marked "Resistance In," is connected to the
rheostat and is in series with the positive terminal
of the ammeter.
" • Th" second binding post, marked "Resistance
4
EQUIPMENT
Out" is a direct connection to the positive term-
inal of the ammeter without passing through the
rheostat.
The third binding post is connected to the
negative terminal of the ammeter for the 50
, ampere scale.
The fourth binding post is connected to the
negative ammeter terminal for the 10 ampere
scale.
Two small binding posts are provided between
the second and third current carrying binding
posts for the use of external shunts. The following
FIGURE 3
shunts (Figure 3) are available with calibrated
leads for connections to the P.E.T. Set:
100 ampere capacity-Part Number ST-232A-2
200 ampere capacity-Part Number ST-232A-3
500 ampere capacity-Part Number ST-232A-1
1000 ampere capacity-Part Number ST -232A-4
The voltmeter leads are permanently attached
to the instrument and are 27" long with alligator
clips on the ends for ease in making connections.
The positive lead is colored red and the negative
lead is black.
Ammeter leads are No.8 flexible cable 37"
long and have pin terminals on one end for
connecting to the current carrying binding posts
and special clips on the other end. The positive
lead is red and the negative black. The ammeter
lead clips have a long tooth on each carner so
that they may be securely connected to wires
with screw holes in the terminals.
 AUTO-LITE ELECTRICAL EQUIPMENT

SERVICE TOOLS - Continued

GAlkil: TeST SET

....... c,.". _ ....... , .... c.1' .""~'.II
T>It rutc.,."IC AUTO-LITe til
......... t ........ _ •
...... -~,-
1:0"".'51'_

. '©'@.~
.~o
II
.. ill

FIGURE 4
FIGURE 5
ST-262 V.C.P. TEST SET
tive condensers: leakage, capacity in microfarads
This test unit (Figure 4) is a very compact set of and 500 volt insulation breakdown test. With it
gauges for general automotive testing.
condensers can be tested either on or off the
The upper right hand gauge is a retard type
vehicle.
pressure gauge with a range of from 0-10-30
Shipped with each tester is an instruction book-
pounds per square inch. It can be used for
let which gives complete details as to its usage.
checking either fuel pump pressure or exhaust
bock pressure. sT-270 UNIVERSAL HORN TEST BRACKET
The upper left hand gauge is a vacuum gauge To properly adjust Auto-Lite horns it is neces-
with a range of 0 - 30" of vacuum. This gauge
is used to check intake manifold vacuum as well • II
as ~hecking the spark advance calibration of
vacuum type distributors.
The lower gauge. is a compression gauge. It FIGURE 6

has a range of 0 - 150 pounds per square inch. sary that they be mounted on a properly de-
It is used for testing engine compression pressure. . signed test bracket (Figure 6.) Do not hold any
Complete operating instructions are included horn in a vise clamped by the horn flange as
in a booklet shipped with each instrument. this may crack the diaphragm.

sT-265 CONDENSER TESTER sT-272 HORN FEELER GAUGE SET

This tester (Figure 5) is a single meter instru- These gauges, illustrated in Figure 7, are for
ment designed to provide three tests for automo- checking the air gap between the armature and
5
 AUT 0 - LITE E L E CT RIC ALE QUI PM'E NT

SERVICE TOOLS - Continued

ST-281-9 ca. Armature - Core Air Gap-
.031 "-.034"

ST-282 VR REGULATOR ADJUSTING TOOL

(Figure 9)
FIGURE 7

core. The set includes two each of ST -272-1 .027

inch thick gauge and ST-272-2 .040 inch thick FIGURE 9

gauge.
This tool is designed for adjusting the air gap
ST-281 VR REGULATOR GAUGES (Figure 8) of vibrating type regulators.
This list includes all necessary gauges for the
ST-283 REGULATOR SPRING TENSION
•.• ST·".'-' ••• j+===,
Z•• #, ..... , ... ..... i
ADJUSTING TOOL (Figure 10)

FIGURE 10

This tool is used to adjust the armature spring

...... $"'. . ,... .0.35:==:= tension on all two charge and small type vibrat-
,041 st·''''! .. !ll ing voltage regulators.

r ... 57-ill/l-S
... I I ST-284 OHMETER
FIGURE 8
This meter (Figure 11) is a' self-contained unit
adjusting and setting the air gaps of the TC and
VR type regulators, namely:

ST-281-1 Armature-Core Air Gop Gauge-

.040"-.042"
ST-281-2 Armature-Core Air Gop Gouge-
.0595"-.0625"
ST-281-3 C.B. Armature - Core Air Gap-
.034"-.038"
ST-281-4 CB. Armoture- Core Air Gop-
FIGURE 11
.055"-.062"
ST-281-5 Armature-Core Air Gop Gauge- used to check the resistance of automotive elec-
.047"-.049" trical windings. Instructions for its correct usage
ST-281-6 Armature-Core Air Gop Gouge- are attached to each meter.
.034"-.038" There are two scale ranges:
ST-281-7 Armature-Core Air Gop Gauge- 0-6 ohms with graduations beginning with .01.
.048"-.051 " 6-600 ohms .
6
• I,""
 ,
AUTO-LITE ELECTRICAL EQUIPMENT

GENERATORS
The generator is a device for changing mechan-
ical energy into electrical energy. Generators
are built in many voltages and design to fit the
special requirements of the application for which
they are intended. Some generators are com-
pletely sealed to exclude moisture or dust. Others
are ventilated by a suction fan usually combined
with the drive pulley. A typical ventilated gen-
erator is illustrated in Figure 29. The air stream
hinge type mounting while large trucks and sta-
tionary engines may use flange, base or barrel
type mounting. Special mountings are often de-
signed to fit applications not adaptable to the
standard hinge or flange types. The type of drive
also varies for different applications.
The generator is the source of all electrical
energy on a car. It supplies power for the ignition,
lights, heater, radio and other accessories. The

-- ----------
- --,.-----
-- --

_.- -
-----
- -
- - --
--
---,- -
--------- - --._--
FIGURE 29
---
---
passing over the armature and field coils carries battery stores some of the generated energy in
away the excess heat and allows a much higher chemical form to be used when the generator is
output without the danger of burning out the not running. The battery is not a source of elec-
armature or fields. Ventilated generators are tricity but only a storage reservoir. In starting for
'/ \'
,,~ed on most automotive and truck applications instance the battery supplies the energy but as
while non-ventilated generators are used on ma- soon as the engine starts the generator begins to
rin(e or tractor applications where dust or water replace the electricity taken from the battery.
'fie likely to cause damage, Thus the generator must be of sufficient capacity
~,Most passenger cars and light trucks use a to supply all of the current used on the car.
/"
26
 AUTO-LITE ELECTRICAL EQUIPMENT

GENERATORS - Continued

sufficient capacity to cronk the engine and sup- 1-

L

ply enough electrical energy for the ignition

" COLD PU

system for starting the engine. "

As the automobile has developed there has " .LU
been an increase in the number of electrical uses.
", ; HOT OUTPUT

L-
The lights have been increased in number and ,
capacity, electric horns have become standard 600 1600 2400 3200 4000 4600 5600 641)0 7200 8000

equipment, electric windshield wipers are being GENEJIATOR R.P.M.

FIGURE 30
used and the newer carS are using solenoid con-
trolled transmissions, electric window lifts, radios third brush generator and its connection to the

and many other electrical accessories. These de- circuit breaker are shown in Figure 3l.
velopments have come gradually and with each This type of unit is restricted to applications

new use of electricity it was necessary to increase requiring low output generators.
B"ITTERY TER/'1/N/9L "B'
the capacity of the generator.
There are two main types of generators. These
are the third brush generator and the shunt gen-
(,' .
erator.

THIRD BRUSH GENERATORS

The output of third brush generators is con-
trolled by one of the following methods: /'P1IN

Adjustable third brush.

Adjustable third brush and two-charge regu-
lator.
Adjustable third brush and vibrating voltage
regulator.
Fixed third brush and vibrating voltage regu-
lator.
I-Third Brush Control
With this type of control the output is varied
I by changing the voltage applied to the field coils
by moving the third brv.sh. Moving this brush in
the direction of armature rotation increases the
output while moving it against armature rotation
FIGURE 31
2-Third Brush Control with TC Regulator
The two charge regulator was developed for
use with t-he third brush generator so that its out-
put varied in accordance with the state of charge
of the battery' The two charge regulator is de-
signed to permit the generator to charge at its
high rate until the voltage reaches a predeter-
mined maximum at which time the outpu~~s· re-

decreases the output. Figure 30 shows a typical duced approximately 50%. The higher output: is
output curve. The internal wiring of a typical produced whenever the demands on the gener-
27
 AUTO-LITE elECTRICAL EQUIPMENT

GENERATORS - Continued
3-Third Brush Control with VR Regulator

" DOT UT When a vibrating type voltage regulator is

" used with a third brush generator the output con-
"
" HOT 0 T
forms closely with the requirements of the battery
and connected load. The regulator holds the gen-
"
• erated voltage constant under wide variations
• OUTPUT WITH C-
"TOR OPEA TI

• of loading. Thus the charging rate varies to allow

800 1600 2400 3200 4000 4800 51100 6400 7200, 8000 a high current when the battery is low or when a
GE:N£R"TOR R.P. M

FIGURE 32
large load is being used. if the battery is fully
charged and there is no accessory load the regu-
ator are large while the lower output is pro-
lator holds the generator output to a low sus-
duced when the battery is full and the connected
taining charge. When high resistance connec-
load is small. A typical charging curve of a third
tions develop in the charging circuit the output
brush generator with a two charge regulator is
is reduced. This prevents the increase in voltage
shown in Figure 32 and the internal connections
obtained when high resistance occurs in a circuit
without a vibrating type regulator or with a two
charge regulator. This elimination of high volt-
age increases the life of lamp bulbs and of the
ignition system.
When the vibrating type regulator is used with
a third brush generator it is possible to use a
much higher capacity generator without danger
of overcharging the ballery. The maximum cur-
rent is still controlled .by the third brush. A typi-
cal charging curve and wiring diagram of a third
B~USH
INSt.lt.I9TEO brush generator with vibrating voltage regula-
I'1A/N BIi't.lSH
C,Ii'Ot.lNOED
tion are shown in Figures 34 and 35. The heavy
I'1A/N BIi'I./SH

"
"
"

FIGURE 33

.' AP!'~<:lXIt.!A"! OUTNT TO FULLY

CHARGEo S,o,TTERY AND WIT'"
The two charge regulator allows a larger ca- NO <':ONNECTED LOAO

pacity generator to be used without overcharging GtNERATOR RP.M.

the battery. FIGURE 3.

28
 AUTO-LITE ElECTRICAL EQUIPMENT

GENERATORS - Continued
shows the internal wiring of a shunt generator
and a voltage and current limiting regulator.

MAINTENANCE A periodic inspection should

PROCEDURE be made of the charging cir-
cuit. The interval between these checks will vary
depending upon the type of service. Dirt, dust
and high speed operation are factors which con-
tribute to increased wear of the bearings, brush-
G.eGVNO£lJ 1'1,.qIN
es, etc. Under normal conditions an inspection of
TO a,qT. the generator should be made each 5000 miles.
FIGURE 35

line indicates the maximum output and the

dotted lines indicate the decrease in output as
the battery becomes charged.

4-Fixed Third Brush with VR Regulator

, ,
APPFlO)(IMAT~ OUTPUT TO FULLY
CHARGED eATTEFlY ANO WITH
The operation of this type is identically the 1>10 CONNECT~ LOAD

•
same as the preceding type except that the posi-
tion of the third brush is not adjustable.
400 800 1200 1800 2<)00 2<100 ~eoD 3i1OO 31100 4000 4400 4800
G<;NERATOR R.P.M.

FIGURE 36
SHUNT GENERATORS

With the development of high output gener-

ators it became desirable to eliminate the de-
crease in output at high speeds and also to lower
the generator speed at which the maximum out-
put is produced. This was done by using a shunt
generator and eliminating the third brush con-
trol. With a shunt generator it is necess.ary to
IN$UlATeD J11;IIIN
provide some method for limiting the maximum SA!lJSH
output of the. generator to a safe value. The G.eot./NDEIJ HI9IN
~I.I$H

~urrent limiting regulator was developed for this

purpose. When a voltage and current limiting
regulator is used in conjunction with a shunt gen-
erator a charging rate is obtained that is fully
dependent on the requirements of the circuit.
Such a curve is illustrated in Figure 36. Figure 37
29
1. Wiring
A visual inspection should be made of all wir-
ing to be sure that there are no broken wires and
that all connections are clean and tight.

", ,'; " ~.~ i !:~ '!"_ " ;" . .....- ,

,'-
 AUTO-LITE ELECTRICAL EQUIPMENT

GENERATORS - Continued
2. Commutat"".. 5. Lubrication
If the commutator is dirty or discolored it can Add 5 to 10 drops of medium engine oil (A

be cleaned by holding a piece of 00 sandpaper good grade of S.A.E. No. 20 oil) to the oilers.
against it while running the armature slowly. Grease cups should be filled with a high melting
Blow the sand out of the generator after clean- point grease and periodically turned down one
ing the commutator. If the commutator is rough turn.
or worn the generator should be removed from GENERATOR At periods of approximately 15,-
the vehicle, the armature removed and the com- OVERHAUL 000 miles the charging circuit
mutator turned down. See page 31 for instruc- should be thoroughly checked and the genera-
tions on this operation. tor removed from the vehicle and reconditioned.
1. Wiring
3. Brushes Be sure that all connections are clean and tight
The brushes should slide freely in their holders. and that there are no broken wires. To check
If the brushes are oil soaked or if they are worn connect an ammeter between the battery term-
to less than one half of their original length they inal of the circuit breaker or regulator and the
should be replaced. See page 32 for servicing lead removed from this terminal. Run the engine
instructions. at a speed equivalent to 20 M.P.H. Adjust the
current to 10 amperes by turning on the lights.
4. Brush Spring Tension At this 10 ampere charging rate a voltage read-
The brush spring tension should be checked. ing should be taken with a 10 volt voltmeter be-
If the tension is excessive the brushes and com- tween the following points. See Figure 38.
mutator will wear very rapidly while if the ten- a. BG to GG 0 volts
sion is low arcing between the brushes and com- b. BG to RG 0 volts
mutatorand reduced output will result. See page c. RG to GG 0 volts
34 for test figures. d. RA to GA .1 volts
VOLTS AMPS OHMS
o 10 o
o 10 o
o 10 o
.I 10 .01 RA
.I 10 .01 o

BB

BATTERY

AR FRAME

FIGURE 38

30
 AUTO-LITE ELECTRICAL EQUl,PMENT

GENERATORS - Continued
e. RS to SS .1 volts STEEL STRIP HELD ON,'
If readings higher than these are obtained the ARMATURE SLOT
wiring should be checked for high resistance
connections.

2. Armature
The armature should be visually inspected for
mechanical defects.
If the commutator is rough or worn it should
be turned down in a lathe. After turning the com-
mutator the mica should be undercut to a depth
of 1/32". When undercutting the mica the cut
should be square and free from burrs. The maxi-
mum eccentricity of the commutator is not to ex-
ceed .0003 inches.
For testing armature circuits it is advisable to
use a set of test probes such as shown in Figure
FIGURE 40
39.
ItQ VOLT UNE
the steel strip will vibrate.

3. Field Coils
TEST POINTS Using the test probes illustrated in Figure 39
check the field coils for both opens and grounds.

10 wArT
To test for open coils. connect the probes to
LAMP

the two leads of each coil. If the lamp fails to

FIGURE 39
To test armatures for grounds connect one
point to the core or shaft (not on bearing sur-
faces) and touch a commutator segment with the
• other probe. If the lamp lights the armature
winding is grounded and the armature should be
replaced.
To test for shorted armature coils a growler
(Figure 40) is necessary. Place the armature on
the growler and hold a thin steel strip on the
armature core. The armature is then rotated
slowly by hand and if a shorted coil is present
31
light the coil is open and should be replaced.
To test for grounds place one probe on the
generator frame and the other to the field coil
terminals. If a ground is present the lamp will
light and the coil should be replaced.
4. Brush Holders
With the test probes check the insulated brush
holder to be sure it is not grounded. Touch the
insulated brush holder with one probe and a
convenient ground ali the C.E. Plate with the
other probe. If the lamp lights it indicates. a
. grounded brush holder.
. ',:dt'L'
 AUTO-LITE ELECTRICAL
GENERATORS - Continued
Inspect the brush holders for distortion and
improper alignment. The brushes should swing
or slide freely and should be perfectly in line
with the commutator segments.
5. Brushes
Brushes that have been subjected to oil or are
worn to one-half or less of their original length
should be replaced.
When replacing brushes it is necessary to seat
them so that they have 100% surface contacting
on the commutator. The brushes should be
sanded to obtain this fit. This can be done by
drawing a piece of 00 sandpaper between the
commutator and brush and against the brush
holder as illustrated in Figure 41. Do not sand
SANDPAPER PULLED
AGAINST BRUSH HOLDER
fIGURE ~I
too much as it merely shortens brush life. After
sanding the brushes blow the sand and carbon
dust ,out of the generator. The generator should
.
then be run under load long enough to secure
a perfect brush fit. Generators are not to be
tested for output until after the brushes are
seated.
6. Assembly of Generator
.. When assembling absorbent bronze bearings
' .. ··.~Iway~. use the proper arbor as these arbors are
",.' ,dei,igrl.ed to give the proper bearing fit.
32
EQUIPMENT
When assembling bearings or end heads that
are equipped with oil wicks always remove the
wick and replace it only after the armature and
end heads are assembled.
Absorbent bronze bearings and wicks should
be soaked in oil before assembling and the boll
bearings should be pocked one half full with a
heat resisting grease before assembly.
7. Lubrication
Generator armatures may be mounted in boll
bearings or in oil absorbent bronze bearings.
The drive end bearing is usually a boll bearing
while the commutator end bearing may be either
ball or absorbent bronze depending on the size
and application of the generator.
Nearly all generators are provided with oilers
at both ends. These oilers are usually of the fol-
lowing types:
a. Hinged top - These are located over the
bearing and should be given 5 to 10 drops .
of medium engine oil every 5000 miles.
b. Swinging type-This type is used only on
the commutator end cap cover and should
be filled full of medium engine oil every
5000 miles.
c. Cup and wick oilers-This type is found
under the bearing. The cup should be re-
moved and filled 'with medium oil every
5000 miles.
d. Grease cups-These are usually located at
the side of the end plates. The cups should
be given one turn every 5000 miles. When
refilling cups use a high melting point
grease.
 AUTO-LITE ELECTRICAL
GENERATORS - Continued
e. Cup oilers-This lype of oiler has a spring
caver and is found at the side of the end
plates. The cups should be filled with medi-
um engine oil every 5000 miles.
When the generator is disassembled and
cleaned the absorbent bronze bearings should
be soaked in oil before assembling and the ball
bearings should be packed one half full with a
high melting point grease. Care must be taken
not to over-lubricate any of the bearings as the
surplus oil may deposit on the commutator or
brushes allowing them to become oil soaked and
seriously affect the operation of the generator.
33
EQUIPMENT
8. Generator Test
After the generator is assembled and the
brushes are properly fitted the generator should
be bench tested under conditions of speed, volt-
age, amperes and temperature as near as pos-
sible the same as when in operation on the car
before installing on the car. See pages 34 to 39
for complete test data.
All generators should be polarized with the
car battery before running. This can be done by
using a jumper from the starting switch battery
terminal to the armature terminal of the gen-
erator.
 AUTO-LITE EL E C T R I C'AL EQUIPMENT

GENERATOR TEST DATA

The following numerical list of Auto-lite gen-
erators shows the rotation, type of control, test
to which it is set and the, brush spring tension.
Test specifications on the following generators
are shown on page 39.
NOTE:-Where the suffix letter has been omit-
ted the test data is the same as given for the
straight nlimber. In a few instances the test data
is not the same and in such cases the units are
listed separately.
ABBREVIATIONS USED IN THE FOLLOWING
TABULATION
CW-Clockwise rotation at the drive end.
CCW-Counter clockwise rotation at the drive
end
CB-Third brush control with circuit breaker
TC-Third brush and two charge regulator
control
VR-Third brush and vibrating voltage regu-
lator
c;VR-Shunt type with vibrating current and
voltage regulator

Spring Spring
Rot. TM' Tension Rot. Test Tension
D.E. Control No. Ounces Unh D.!. Control No. Ounces
CW CB GAE-O 20-26 GAR-4316 CCW CB GAR-o 17-22
CB
~~W CB GAE-O
GAE-O
20-26
20-26
GAR-4502
GAR-4513
CW
CW
C8.
CB
GAR-O
GAR-O
18-22
18-22
CW TC GAE-O 20-26 GAR-4515 CW CB GAR-O 18-22
CCW TC GAE-O 20-26 GAR-4518 CCW CB GAR-O 18·22
CCW CB GAE-O 20-26 GAR·4520 CCW CB GAR-O 18-22
CW CB GAE-o 20-26 GAR-4521 CW CB GAR-O 18-22
CW CB GAE-O 20-26 GAR.4522 CW CB GAR-O 18-22
CW CB GAE-O 20-26 GAR-4524 CW CB GAR·O 18·22
CW TC GAE·o 20-26 GAR·4525 CW CB GAR-O 18-22
CW TC GAE-o 20·26 GAR-4527 CCW CB GAR-O 17-22
CW TC GAE·o 20-26 GAR-4534 CW CB GAR-O 18-22
CW TC GAE-o 20·26 GAR·4535 CW CB GAR-O 18-22
CCW TC GAE-O 20-26 GAR·4536 CCW CB GAR-O -r 8-22
CCW CB GAE-O 20·26 GAR-4537 CW CB GAR-O 18-22
CW TC GAE-o 20-26 GAR·4540 CW CB GAR·O 18-22
CCW TC GAE·o 20-26 GAR-4541 CW CB GAR-O 18·2.2
CW TC GAE-o 20·26 GAR·4542 CCW CB GAR-O 17-22
GAG-4133 CW CB GAG-O
GAR·4543 CW CB GAR-O 18-22
22·27 GAR-4544 CCW CB GAR-O 17-22
.Ci3AG:4145 CW TC GAG-O 22-27 GAR-4545 CW CB GAR-o 18·22
·GAG-4146 CW TC GAG-O 22-27 GAR-4546 CCW CB GAR-O 17·22
. GAG-4147 CW CB GAG-O 22-27 GAR·4547 CW CB GAR-O 18-22
GAG'4148 CW CB GAG-O 22-27 GAR-4548 CCW TC GAR-O 17-22
-GAG-4t49 CW TC GAG-O 22-27 GAR-4549 CW CB GAR-O 18·22
. GAG-4150 CW CB GAG·O 22-27 GAR-4550 CW TC GAR-O 18-22
GAG-4151 CCW CB GAG-O 22-27 GAR-4551 CCW TC GAR-O 18·22
GAL-4336 CW CB GAL-O 17-22 I
GAR-4553 CCW TC· GAR-O 18-22
GAL-4340 CCW CB GAL-o 17-22 GAR·4554 CW CB GAR-O 18-22
GAR·4555 CW TC GAR-O 18-22
GAM-4504 CW CB GAM-O 18-22 GAR-4601 CW CB GAR-5 50-60
'GAM-4601 CW CB GAM-O 18-22 GAR·4603 CW CB GAR-5 50·60
GAP-4133 CW CB GAP-O 22-27 GAR·4604 CW CB GAR-3 50-60
.13AP-4135 CW (B GAP-O 22-27 GAR·4605 CW TC GAR-4 50-60
\~AP·4140 CW CB GAP-O 22-27 GAR-4606 CW TC GAR-3 50-60
57 CW CB GAP-O 22-27 GAR-4607 CW. CB GAR-3 50-60
58 CCW CB GAP-O 22-27 GAR·4608 CW TC GAR-5 50-60
59 CW CB GAP-o 22-27 GAR-4609 CW TC GAR-4 50-60
60 CCW CB GAP·O 22-27 GAR-4610 CW TC GAR-4 50·60
GAR·4611 CW TC GAR-5 50-60
CW CB GAR-O 17-22 GAR-4612 CW TC GAR-3 50·60
.34
; , .;,. -.,."
 f AUTO-liTE eleCTRICAL EQUIPMENT

GENERATORS - Continued
Spring Spring
~ Rot. T.., Tension Rot. Test Tension
Unit D.E. Control No. OuncM Unit D.E. Control No. Ouneu
.~
GAR-4613-3 CW TC GAR·3 50-60 GAS-4152 CCW C8 GAS-O 15-20
GAR-4613-4 CW TC GAR-4 50-60 GAS-4157 CW TC GAS-O 15-20
GAR-4614-4 CW TC GAR-4 50·60 GAS-4159 CW TC GAS-1 15-20
GAR-4614-5 CW TC GAR-5 50-60 GAS-4160 CW C8 GAS-O 15-20
GAR-4616 CW TC GAR-3 50-60 GAS-4161 CW C8 GAS-O 15-20
GAR-4617 CW TC GAR-3 50-60 GAS-4162 CW C8 GAS-o 15-20
GAR-4618 CW C8 GAR-2 50-60 GA5-4163 CW TC GAS-O 15-20
GAR-4619 CW TC GAR-3 50-60 GAS-4164 CW C8 GAS-O 15-20
GAR-4620 CW TC GAR-5 50-60 GAS-4165 CW TC GAS-O 15-20
GAR-4621 CCW TC GAR-3 50·60 GAS-4166 CCW C8 GAS-1 15-20
GAR-4622 CW CB GAR-3 50-60 CW TC GBB-o 22-27
GAR-4623 CW TC GAR-4 50-60 GBB-4304
GAR-4624 CW TC GAR-5 50-60 GBE-4201 CW C8 GBE-o 50-60
GAR-4625 CW TC GAR-5 50-60 G8E-4202 CCW CB GBE-O 50-60
GAR-4626 CW CB GAR-3 50-60 GBE-4203 CW C8 GBE-o 50-60
GAR-4627 CW TC GAR-3 50-60 GBE-4204 CCW C8 G8E-0 50-60
GAR-4630 CW TC GAR-5 50-60 GBE-4205 CW C8 ClBE-O 50-60
GAR-4631 CW TC GAR-5 50-60 GBE-4206 CCW CB GBE-o 50-60
GAR-4632 CW CB GAR-3 50-60 G8E-4207 CCW C8 GBE-O 50-60
GAR·4633 CW C8 GAR-3 50-60 GBE-4208 CW C8 G8E-0 50-60
GAR-4634 CW CB GAR-2 50-60 GBE-4209 CCW TC GBE-o 50-60
GAR-4635 CW TC GAR-5 50-60 GBE-4301 CW C8 GBE-O 17-22
GAR-4701 CW TC GAR·6 18-22
GAR_4702 CW CB GAR-O 18-22 GBG-4601 CW CVR GBG-O 23-26 .
GBG-4602 CW CVR GBG-o 23-26
GAS-4102 CCW CB GAS-O 15-20 GBG-4603 CW CVR GBG-o 23-26
I
•
GAS-41 02-1
GAS-4102A
GAS-4102B
CCW
CCW
CB
C8
CB
GAS-1
GAS-1
GAS-1
15-20
15-20
15-20
GBG-4604
GBG-4606
G8G-4607
CW
CW
CW
CVR
CVR
CVR
GBG-O
GBG-O.
GBG-o
CCW CW CVR GBG-o
GAS-4102C CCW CB GAS-O 15-20 GBG-4608
GAS-4103 CW CB GAS-1 15-20 GBG-4609 CW CVR GBG-O'
GAS-4104 CW CB GAS-O 15-20 G8G-4610 CCW CVR GBG-o
GAS-41 04·1 CW CB GAS-1 15-20 G8G-4611 CW CVR GBG-o
GAS-4104A CW CB GAS-O 15-20 GBJ-4601 CW TC GBJ-O
GAS-4104B CW CB GAS-O 15-20
GAS-4106 CW CB GAS-O 15-20 GBK-4601 CW C8 GBK-2·
.' GAS-4108 CCW CB GAS-O 15-20 G8K-4602 CW TC G8K-1 .
'u,,,GAS-4110 CW C8 GAS-O 15-20 GBI<-4603 CW C8 GBK-o
. GAS-4111 CCW C8 GAS-O 15-20 G8K-4604 CW C8 GBK-O
GAS-4114 CCW CB GAS-O 15-20
GAS-4119 CW CB GAS-O 15-20 GBM-4601 CW C8 GBM-O
GAS-4120 CW C8 GAS-O 15·20 GBM-4602 CW . C8 GBM-O
GAS-4120-1 CW CB GAS-1 15-20 GBM-4603 CW CB GBM-1
GAS-4120A CW C8 GAS-O 15-20 G8M-4604 CW CB GBM-1 50-60
GAS-4124 CCW CB GAS-1 15-20 GBM-4606 CW CB GBM-1 50-60
GAS-4125 CW C8 GAS-O 15-20 GBM-4607 CW CB GBM-1 50-60
GAS-4125-1 CW CB GAS-1 15-20 GBM-4608 CW CB GBM-O 50-60
GAS-4126 CCW CB GAS-O 15-20 GBM-4608C CW CB G8M-1 50-60
GAS-4128 CW CB GAS-O 15-20 GBM-4609 CW CB GBM-O 50-60
GAS-4129 CW CB GAS-O 15-20 GBM-4610 CW CB GBM-5 50-60
GAS-4131 CW CB GAS-1 15-20 GBM-4611 CW CB GBM·4 50·60
GAS-4132 CCW CB GAS-O 15-20 GBM-4612 CW CB GBM-O 50-60
GAS-4136 CW TC GAS·1 15-20 GBM-4613 CW CB GBM-1 50-60
GAS-4139 CW CB GAS-O 15-20 GBM-4616 CW TC G8M-1 . 50-60
GAS-4140 CW CB GAS-O 15-20 GflM-4617 CW CB GBM-5 50-60
GAS-4141 CW CB GAS-O 15-20 GBM-4619 CCW CB G8M-5 50-60
GAS-4144 CW CB GAS-O 15-20 GBM-4620 CW CB GBM-1 50-60: .
GAS-4145 CW TC GAS-O 15-20 GBM-4801 CCW C8 GBM-5 37-44t
GAS-4148 CW TC GAS-1 15-20 . GBM-4802 CW TC G8M-5 37-44+
GAS-4149 CCW TC GAS-1 15-20 GBM-4803 CW C8 GBM-1 _ 37-44.·.· .
GAS-41SO CCW CB GAS-1 15-20 GBM-4804 CW CB GBM-5 37-44ti\'
GAS-4151 CW CB GAS-1 15-20 GBM-4805 CW CB GBM-5 37-44f'
tThird brush spring tension should be 50 to 60 ounces.

35
 AUTO-LITE ELECTRICAL EQUIPMENT

GENERATORS - Continued
Spring Spring
Rot. Test Tension Rot. Test Tension
Unit D.E. Control No. Ounces Unit D.E. Control No. Ounces

GBM-4806 CW CB GBM-4 37-44 t GCB-4815 CW CYR GCB-O 64-68

GBM-4807 CW TC GBM-1 37-44t GCB-4816 CW CVR GCB-o 64-68
GBM-4808 CW TC . GBM-6 37-44t GC8-4817 CW CVR GCB-o 64-68
GBM-4809 CW TC GBM-5 37-44 t GCB-4818 CW CVR GCB-o 64-68
GBM-4810 CW CB GBM-1 37-44 t GCB-4820 CW CVR GCB-O 64-68
GCB-4821 CW CVR GCB-o 64-68
GBR-4501 CW CB GBR-3 18-22
GBR-4502 CCW CB GBR-3 18-22 GCD-4801 CW CYR GCD-o 55-65
GBR·4601 CW TC GBR-5 50-60 GCD-4803 CW CVR GCD-o 55-65
GBR-4602 -CW TC GBR-4 50-60 GCD-4804 CW CVR GCD-O 55-65
GBR-4603 CW TC GBR-4 50-60 GCD-4805 CW CVR GCD-o 55-65
GBR-4604 CW TC GBR-S 50-60 GCD-4806 CCW CVR GCD-O 55-65
GBR-4605 CW TC GBR-5 50-60 GCD-4807 CW CVR GCD-O 55-65
GBR-4607 CW TC GBR-5 50-60 CW CVR GCE-O 64-68
GBR-4608 CW TC GBR-5 50-60 GCE-4803
GBR-5 50-60 GCE-4804 CW CVR GCE-O 64-68
GBR-4609 CW TC GCE-4806 CW CYR GCE-O 64-68
GBR-4611 CW TC GBR-5 50-60 CVR GCE-O 64-68
CW TC GBR-5 50-60 GCE-4807 CW
GBR-46H GCE-4808 CW CVR GCE-O 64-68
~
GBS-4501 CCW CB GBS-l 18-22 GCE-4809 CW CVR GCE-o 64-68
GBS-4502 CW CB GBS-1 . 18-22 GCE-4810 CW CVR GCE-o 64-68
GBS-4602 CW TC GBS-O 50-60 GCE-4812 CW CVR GCE-O 64-68
CW TC GBS-O 50-60 GCE-4813 CW CVR GCE-O 64-68
CCW TC GBS-O 50'60 GCE-4814 CW CVR GCE-O 64-68
GCE-4815 C\'II CVR GCE-O 64-68
CW TC GBU-O 50-60 GCE-4816 CW CVR GCE-O 64-68
CW TC GBU-O 50-60 GCE-4817 CW CYR GCE-o 64-68
CCW TC GBU-O 50-60 GCE-4822 CW CYR GCE-O 64-68
CW TC GBU-O 50-60
CW TC GBU-O 50-60 GCG-4601 CCW No GCG-o 24-36
CW CB . GBU-O 50-60 GCH-4601 CW CVR GCH~O 23-26
CW TC G8U-0 50-60 GCH-4602 CW CVR GCH-O 23-26
CW CB GBU-O 50-60 GCH-4603 CW CVR GCH-O 2.3-26
CCW CB GBU-O 50-60 GCH-4604 CW CVR GCH-o 23-26
CW TC GBU-O 50-60 CW CVR GCH-o 23-26
CW TC GBU-O 50-60 GCH-4606
50-60 GCH-4607 CW CVR GCH-1 23-26
CW TC GBU-O GCH-4608 CW CYR GCH-1 23-26
CCW CB GBU-O 50-60 CW CYR GCH-O 23-26
GCH-4609
CW CYR GBW-O 53 Max. VR GCJ-O 53 Max.
CW CVR GBW-O 53 Max. GCJ-4801 CW
53 Max. GCJ-4802 CW YR GCJ-O 53 Max.
CW CVR GBW-O GCJ-480J CW ._ YR GCJ-O 53 Max.
CW CYR GBW-O 53 Max. CW CB GCJ-1 53 Max.
CW CYR GBW-O 53 Max. GCJ-4804
53 Max. GCJ-4805 CW YR GCJ-O 53 Max.
CW CVR GBW-1 GCJ-4807 CW VR GCJ-2 53 Max.
CW CVR GBW-1 53 Max. GCJ-4808 CW VR GCJ-O 53 Max.
CW TC GBX-5 41-52 GCJ-4810 CW YR GCJ-2 53 Max.
CW TC GBX-5 41-52 GCJ-4811 CW VR GCJ-o 53 Max.
GCJ-4812 CCW CB GCJ-3 53 Max.
GBY-4601 CW TC GBY-5 41-52 GCJ-4813 CCW CB GCJ-3 53 Max.
GBY-4801 CW TC GBY-5 64-68 GCJ-4814 CW CB GCJ-3 53 Max.
GBY-4802 CW TC GBY-5 64-68 53 Max:
CCW ~~'j'
GCJ-4815 CW GCJ-3
CW CYR GCB-O 64-68 GCJ'4816 ',','" GCJ-3 53 Max.
GCB-4601
GCB-4802 CW CYR GCB-o 64-68 GCK-4801 CW (:VR GCK-O 53 Max.
GC8-4803 CW CYR GCB-O 64-68 GCK-4802 CW CVR GCK-O 53 Max.
GCB-4804
GCB-4805
CW
CW
CYR GCB-O
CVR GCB-O
64-68
64-68
GCK-4804 cew CVR GCK-1
GCK-O
53 Max.
53 Max.
GCK-4805 CW CYR
GCB-4806 CW CYR GCB-O 64-68 GCK-4806· . eW, CVR GCK-1 53 Max .
CW CYR GCB-O 64-68 GCK-4807 J:.CW CVR GCK-1 53 Max.
CW .CVR GCB-O 64-68
CW CYR GCB-O 64-68 GCM-4802 CW TC GCM-4 53 Max.
CCW CVR GCB-O 64-68 GCM·4803 CW CB GCM-4 53 Max.
CW - CYR GCB-O 64-68 GCM,4804 CW TC GCM-4 53 Max.
sprin_9 _ten.si~n should ,be.50 to 60 o·unces.

36
 AUTO-LITE ELECTRICAL EQUIPMENT

GENERATORS - Continued *'

Spring Spring
f'-, Rot. Test Tension Rot. Test Tension
Unit D.E. Control No. Ounces Unit D.E. Control No. Ounces
GCM-4805 CCW TC GCM-4 53 Max.
GCW-4805 CW eVR GCW-o 64-68
GCM-4806 CW CB GCM-4 53 Max.
GCW-4806 CCW CVR GCW-O 64-68
GCM-4807 CW CB GCM-4 53 Max.
GCM-4808 CW CB GCM-4 53 GCX-4501
Max. CW CB GCX-o 7-10
GCM-4809 CW CB GCM-4 53 GCX-4502
Max. CW CB GCX-O 7-10
GCM-4810 CW TC GCM-4 53 GCX-4503
Max. CW CB GCX-o 7-10
GCM-4811 CW CB GCM-4 53 Max.
GCY-4601 CW CVR GCY-o 23-26
GCM-4812 CW CB GCM-O t53 Max.
GCY-4603 CCW CVR GCY-1 23-26
GCM-4814 CCW CB GCM-o t53 Max.
GCY-4604 CCW CVR GCY-1 23-26
GCM-4815 CW TC GCM-4 53 Max.
GCM-4816 CW TC GCM-4 53 GCZ-4803
Max. CCW CB GCZ-O 53 Max.
GCM-4818 CW CB GCM-O t53 GCZ-4805
Max. CCW CB GCZ-O 53 Max.
GCM-4820 CCW CB GCM-O t53 GCZ-4806
Max. CW CB GCZ-o 53 Max.
GCM-4821 CW CB GCM-O t53 GCZ-4807
Max. CW CB GCZ-o 53 Max.
GCM-4822 CW TC GCM-4 53 Max.
GDA-4801 CW
GCM-4824 CW CB GCM-4 53 Max. CVR GDA-O 53 Max.
GCM-4825 CW CB GCM-4 53 GDA-4802
Max. CW CVR GDA-O 53 Max.
GCM-4827 CW TC GCM-O t53 GDA-4803
Max. CW CVR GDA-O 53 Max.
GDA-4804 CW CVR GDA-O 53 Max.
GCO-4801 CW CVR GCO-o 53 Max. GDA-4805 CW CVR GDA-o 53 Max.
GCO-4802 CW CVR GCO-O 53 Max. GDA-4806 CW CVR GDA-o 53 Max.
GCO-4803 CW CVR GCO-o 53 Max. GDA-4807 CCW CVR GDA-O 53 Max.
GCO-4804 CW CVR GCO-O 53 Max. GDA-4808 CW CVR GDA-O 53 Max.
GCO-4806 CW CVR GCO-O 53 Max. GDA-4809 CW CVR GDA-1 53 Max.
GCO-4807 CW CVR GCO-o 53 Max. GDA-4810 CW CVR GDA-1 53
GCO-4808 CW CVR GCO-o 53 Max. GDB-4802 CCW CB GDB.2
GCP-4801 CW CVR GCP-o 53 Max. GDB-4803 CW CB GDB~2
GCP-4802 CCW CVR GCP-o 53 Max. GDB-4804 CW TC GDB-O
GDB-4805 CCW TC GDB-o
GCR-4801 CW CVR GCR-O 53 Max. GDB-4810 CCW TC GDB-O
GCR-4802 CW CVR GCR-O 53 Max. GDB-4812 CCW TC GDB-O
GCR-4803 CW CVR GCR-O 53 Max. GDB-4813 CCW TC GDB-2
GCR-4804 CW CVR GCR-O 53 Max. GDB-4814 CW TC GDB-o
GCS-4802 CW TC GCS-5 53 Max. GDC-4601 CCW No GDC-O
GCS-4803 CW TC GCS-5 53 Max. GDE-4101 CW TC
GCS-4804 CW TC GCS-5 53 Max. GDE-O
GCS-4805 CW TC GCS-5 . 53 Max. GDE-4102 CCW TC GDE-o
GCS-4806 CW TC GCSc5 53 Max. GDE-4103 CCW TC GDE-o
GCS'4807 CCW CB GCS-1 53 Max. GDE-4104 CCW TC GDE-o
GCS-4808 CW TC GCS-5 53 Max. GDE-4105 . CCW TC GDE-o
GCS-4809 CW TC GCS-5 53 Max. GDE-4106 CCW TC GDE-O
GCS-4810 CW TC GCS-5 53 Max. GDF-4801 CW VR GDF-o 53 Max.
GCS-4811 CW TC GCS-5 53 Max. GDF-4802 CW VR GDF-O 53 Max.
GCS-4812 CW TC GCS-5 53 Max. GDF-4803 CW CB G~il,,'''' 53 Max.
GCS-4813 CW TC GCS-5 53 Max. GDF-4804 CW VR OO-o:?,;, 53 Max.
GCS-4814 CW TC GCS-5 53 Max. GDF-4805 CCW' CB GDF~2~'";';" 53 Max.
GCS-4815 CW TC GCS-5 53 Max. GDF-4806 CW CB GDF-2 53 Max.
GDF-4807 CW CB GDF-2 53 Max.
GCT-4801 CW CB GCT-1 53 Max. GDF-4808 CCW CB GDF-2 53 Max.
GCT-4802 CW VR GCT-O 53 Max. GDF-4812 CW VR GDF-O 53 Max.
GCT-4803 CW CB GCT-1 53 Max .. GDF-4813 CW CB GDF-2 53 Max.
GCT-4804 CW VR GCT-o 53 Max. GDF-4814 CCW CB GDF-2 53 Max.
GCT-4S05 CW VR GCT-O 53 Max. GDF-4815 CCW VR GDF-o 53 Max.
GCT-4806 CW VR GCT-O 53 Max.
GCT-4807 CW 'VR GCT-o 53 Max. . GDG-4501 CW No GDG-O 7-10
GCT-480B CW VR GCT-O 53 Max. GDJ-4801 CCW CVR GDJ-o
GCT-4810 CW CB GCT-1 53 Max. GDJ-4802
GCT-4811 .' -"CW CB GCT-1 53 Max. CW CVR GDJ-O
GCT-4812 CW VR GCT-1 53 Max. GDJ-4803 CW CVR GDJ-O
GDJ-4804 CW CVR' GDJ-O .
GCW"1I802' .(CW CVR GCW-o 64_68 GDJ-4805 CW CVR'GDJ-O
GCW14804. CW CVR GCW-O 64-68 GDJ-4806 CW CVR liideDJ-O
tT~'!rd brush spri-ng tension should be -50 to 60 ounces: '5,'-~1 '
 i,
AUTO-LITE ELECTRICAL EQUIPMENT "

GENERATORS - Continued
Spring Spring
Rat. Test Tension Rot. Tes.t Tension
Un if D.E. Control No. Ounces Unit D.E. Control No. Ounces
GOM-4803 CW CVR GOM-1
55-65 GEB-4825 CW CVR GEll-o 64-68
GOM-4804 CW CVR GOM-1
55-65 GEB-4826 CW CYR GEB-3 64-68
GOM-4806 CCW CVR GOM-1
55-65 GEB-4827 CW CVR GEB-O 64-68
GOO-4601 CW GEB-4828 CW CYR GEB-O 64-68
CVR GOO,1
23-26 GE8-4829 . CW CYR GEB-o 64-68
GOP-4801 CW CVR GOP-O
53 Max. GEC-4801
GOP-4802 CW CVR CW VR GEC-O 53 Max.
GOP-O
53 Max.
GOP-4803 CW CVR GOP-o
53 Max. GED-4501 CW CB GED-o 7-10
GDP·4809 CW CVR GOP-O
53 Max. GEE-4501 CW CB GEE-O 7-10
G05-4801 CW VR GEE-4502 CW CB GEE-O 7·10
G05-0
53 Max.
G05-4802 CW VR G05-o
53 Max. GEF-4801 CW CVR GEF-o 53 Max.
G05·4803 CW CB G05-1
53 Max. GEF-4802 CCW CVR ' GEF.o 53 fviax.
CW CVR GOT·O
55-65 GEG-4801 CW CVR GEG·o 64·68
'CW CVR GOT-O
55-65 GEG·4302 CW CVR GEG-o 64·68
CW CVR GOT-O
55-65 GEG·4803 CW CYR GEG-o 64·68
.CW_ CB GEG-4805 CW CYR GEG·O 64·68
GOU-o
7-10 GEG-4806 CW CVR GEG-O 64·68
CW. CYR 23·26 '
GOW-o GEG·4807 CW CYR GEG·o 64·68
CW·.:,' CVR ,GOW-O
23·26 GEG·4809 CW CVR GEG·o 64·68
GEG-4810 CW CVR GEG-o 64·68
GOY-O
15·20 GEG-4811 CW CVR GEG-o 64·68
GOY-o
15-20 GEG-4812 CW CVR GEG-O 64·68
GOZ-o
53 Max. G£G·4813 CW CYR' GEG-O 64·68
GOZ-o
53 Max. GEG·4814 CCW CYR GEG-O 64·68
GOZ-O
53 Max. GEG·4815 CCW CYR GEG-1 64·68
GOZ·O
53 Max. GEG-4816 CCW CYR GEG·1 64·68
CW,' 53 Max.
GOZ·O GEG-4817 CW CYR GEG-1 64·68
CW GOZ-O
53 Max. GEG-4818 CW CYR GEG-O 64-68
CCW 53 Max.
GOZ·O GEG-4819 CCW CVR GEGcO" 64-68
" CC,W GOZ-O
53 Max. GEG-4820 CCW CVR GEG·1 64-68
GEG-4821 CW CVR GEG-o 64·68
CW CYR ' ~EA-O 53 Max. GEG-4822 CW' CYR GEG-o 64·68
CW CVR GEA-1 53 Max.
CW CVR GEA-O 53 Max. GEH·4802 CW CVR GEH-O 64-68
CW CVR GEA-o 53 Max. GEH-4803 CCW CYR GEH-1 64-68
GEH·4804 CW CYR \ GEH·1 64·68
CW CVR GEB·o 64·68 GEH·4805 CW CYR GEH-o 64-68 ,
CW CYR GEB-O 64·68 GEH·.1806 CW CYR GEH-o 64·6;8
CW CYR GEB·2 64-68 "!.,,, ".'-.

CW CVR GEB-o 64·68 GEJ.4801 CW CYR GEJ-O 53 Moc,*,

CW CVR, GEB-O "; 64-68 GEK.4801 CCW CB ;;~,,(jEK-O 23.26
CW CVR GEBcO '64·68
CW CVR GE8·0 64-68 GEO·4801./, CCW CB ·-·:&EO.3 53Max.
CW' CVR GEB.o 64-68 GEO-4802::" ' CW CB GEO·3 53 Max. '
CW CVR GEB-O 64-68 GEO-4803"" CW 1C GEO-3 53 Max.
CW CYR GE8-0 64-68 GEO-4804 CCW CB GEO·3' 53 Max.
'CW CVR GE8·0 64-68 GEO-4805 CW CB GEO-3 53 Max.
CW CVR GEB-O 64-68" GEO-4806 CCW CB GEO-3 53 Max.
CW CVR GEB-O 64·68 GEO-4807 CCW CB GEO·3 53 Max.
CW CVR GEB-O 64-68 GEO-4808 CCW 'TC GEO-3 53 Max.
CW CVR GEB-O 64-68 GEO·4809 CW CB GEO·-3 53 Ma.,
CW . CVR GEB-O 64-68 .
CW CVR' GEB·O 64-68 GEP-4801 CW t GEP·O 53 Max,
AH(.>.".--._
CW', CYR GEB-O 64-68 GER-4801 CW VR (':leeR,O ' 53 Max.
CCW 'CVR GEB-o 64·68 - "'.'j!i

CCW CVR G£B·O 64·68 GE5-4801 cW CYR GESc'O 53 Max ..

CW CVR GEB-1 64-68 GET-4501 CW CB. GET-O 7-10 '
CW, CVR ' GEB-O 64·68
CW CYR ,GE8-0 64·68 GEW-4.801 CCW GYR GEW-o" 64'68
CCW CVR GEB·O 64-68 GEW-4802 CW, CVR GEW·O 64·68
CW CVR GEB-l• . 64-68 GEW·4803 CW CYR GfW-O .64-68
• "<',,'

38
'0
 AUTO-LITE ELECTRICAL EQUIPMENT

GENERATORS - Continued
Spring Spring
Rot. r.., Tansion R.t. rest Tenlion
Unit D.E. Control No. Ounce. Unit O.E. Control No. Ounce.
GEW-4804 CW CVR GEW-o 64-68 GFA-4802 CCW CB GFA-2 53 Max.
GEW-4805 CCW CVR GEW-o 64-68 GFA-4803
C~,,~"
, ' , , , , ,CB"
,8
GFA-2 53 Max','

~cW'~~
GEX-4801' CCW CVR GEX-o 64-68 GFA-4804 GFA-2 53 Max.
GFA-4801 CW TC GFA-2 53 Max. GFA-4805 GFA-2 53 Max.
Field Current Fi.ld Current
Test at 6.0 Volts Cold Output Max. Test at 6;d'vQlts Cold Output Max.
;;'P'id)

~
No. (Amperes) Volts Amps. R.P.M. No. Vol.. Amps. R.P.M.
GAE-O 1.9-2.1" 15.0 10.5-12.5 GCS-l ,:,,:56-3.94 8.0 13.0-15.0
GAG-O 4.08-4.52 8.0 15.0-17.0 GCS-5 " ,56-3.94 8.0 "19.0-21.0
GAL-O 3.51-3.89 8.0 16.0-18.0 , GCT-o ;:+.40-1.60* 15.0 12.0-13.0
GAM-o 3.89-4.31 8.0 15.5-17.5 GCT-l "1.40-1.60* 15.0 8.0-9.0
GAP-O 2.85-3.15 8.0 15.0-17.0 GCW-o 1.35-1 ;50' 15.0 17.0
GAR-o 3.51-3.89 8.0 15.0-17.0 GCX-o 3.9-4.4 7.0 2.0
GAR-2 3.70-4.10 8.0 17.0-19.0 GCY-O 1.19-1.32* 15.0 33.0
GAR-3 3.70-4.10 8.0 19.0-21.6 GCY-l 1.19-1.32* 15.0 20.0
GAR-4 3.75-4.15 8.0 22.4-24.4 GCZ-o 1.90-2.10 8.0 20.0-22.0
GAR-5 3.51-3.89 8.0 20.4-22.4 GDA-O 1.66-1.84 8.0 28.0'/;
GAR-6 3.51-3.89 8.0 20.5-22.5 GDA-l 1.66-1.84 8".0 25.0
GAS-O 3.80-4.20 8,0 13.3-15.3 GDB-2 3.22-3.58' 15.0,,'
GAS-l 3.80-4'.18 8.0 6.6.7.6 GDC-O§ 1.3-1.6*
GBB-o 3.32-3.68~ 15.0 16.0-18.0 3.80-4.20
GDE-O
GBE-o "2.75-3.05¥ 15.0 14.0-16.0 GDF-o 1.90-2.10 .
GBG-o 1.38-1.52' 15.0 40.0 1065 GDF-l 1.90-2.10
G8J-0 4.18-4.62 8.0 24.0-26.0 GDF-2 1.90-2.10
3.94-4.36 8.0 19.0-21.0 GDG-O 3.90-4.40 7.0
3.94-4.36 8.0 21.0-23.0 GDJ-O 1.48-1.64* 15.0
4.08-4.52 8.0 15.5-17.5 GDM-l 1.41-1.56'. 15.0
3.80-4.20 8.0 19.0-21.0 GDO-l 1.10-1.30 8.0 '"
3.80-4.20 8.0 17.0-19.0 GDP-o 1.45-1 .65 * 15.0
3.80-4.20 ' 8.0 10.0-12.0 GDS-o 1.65-1.82 8.0
3.80-4.20 8.0 14.0-16.0 GDS-l 1.65-1.82 8.0
3.80-4.20 8.0 8.0-10.0 GDT-o 1.58-1.79 8.0' ""
4..1 3-4.57 a.o 16.0f 18.0 GDU-O 3.5-3.9 8.0
4.13-457 8.0 25.0-27.0 GDW-o .87- .97t 30.0
4.18-4.62' 8.0 21.0-23.0 GDY-o 2.24-2.48' 15.0
3.23-3.57' 15.0 10.0-12.0 GDZ-O 1.60-1.78 8.0
3.23-3.57" 15,0 9.6-10.6 GEA-O 1.57-1.75 8.0
3.51-3.89 ;'S.O 9.7-11.7 GEA-l 1..57-1.75 8.0
1.66-1.84 8.0 22.0 1800 GEB-o 1.60-1.78 8.0
1.66-1.84 ,," " ,8.0 14,0 1380 GEB-l 1.60-1.78 8.0
~',&S'3.1 5 8.0 28.8~30.8 GEB;2 1.60-1 .78".,8.0> ", "
2.66-.2.94 8.0 20.0-22.0 GEB-3 1.60-1.788.0
1.50-1.70 .8.0 25.0 1025 GEC-O 1.60-1.78 . 8.0
1.37-1.52' 15.0 20.0 1110 GED-o 1.87-2.06' 15.0 0.0
1.66-1.84 8.0 30.0 1500 GEE-O 2.25-2.48 8.0 13.0-15:0
2.3-2.4 8.0" 30.0 4010 GEF-o 1.40-1.58* 15.0 18.0
1.17-1.29 8,0 40.0 975 GEG-o 1 .60-1. 78 8.0 ',4.0.0
1.17'1.,,29 8.. 0 5 0 . 0 1025 GEG:l 1.60-1.78 8.0 20.0
1.9'2.1 8.0 24.0-26.0 GEH-O 1.38-1.53' 15.0 17.0
L9.2.1 8.0 17.0-19.0 GEH-l 1.38-1.53' 15.0 10.0
1 1 8.0 29.0-32.0 GEJ-o 1.65-1.82 8.0 16.0 "
1 8.0" 17.0-19.0 GEK-O 2.65-2.92' 1·5.0 21
15.0 ,,12.0 1500 " GEO-3 1.65-1.82 8.0 1
'15.0 8.0 1275 1.65-1 8.0 1
8.0 15.0-17.0
8.0 ,,21.0:23.0
8.0 28.0 1850
8.0 12.0, 1275
15.0 15.0 1565
~•., at 5.0 Vol~,jl!,d 165 Max. AlII"..
Lb,. af 11~ Ma~~' .(MPS. and 10.0 Volts.
 AUTO-LITE ELECTRICAL
RELAYS AND REGULATORS
CB, CBA and RA CIRCUIT BREAKERS'
DESCRIPTION The functian of a circuit
AND FUNCTION breaker in automotive elec-
trical equipment is to automatically open and
close the circuit between the generator and the
storage battery.
It consists of" on electromagnet and a set of
contacts. The electromagnet has two windings;
the shunt coil connected across the generator
a voltmet~r, and the other a series coil con-
in:sllrl~~ with the generator output like
an ammeter. (See Figure 42)
.en .the generator is charging the battery
current is flowing through both windings in
,.,.,."." ... ~,sa'11e direction. When the current flows from
battery to the generator, the current is flow-
through the shunt coil in one direction and
through the series coil in the opposite direction.
The circuit breaker contacts consist of one
',m.c)vable cantact mounted on an armature oper-
by the electro magnet, while the other is a
'?1\f,'~tc"ic>nclrv contact. These contacts are held open
by an" armature spring.
The,s~.qy,en.ce-of operation of the circuit br,.ak-
" . "~;~:i'~'!
ar ur;1it is,.(;i$follows:
:",V{h.,n the aelner·ai,,. is not rvnning, tne,.:~c)Ac'
the gener(ltor' ... :.:'
"
EQUIPMENT
the voltage builds up at the generator terminal
,
and in the shunt coil. As soon as the voltage
reaches the value for which the circuit breaker
is calibrated, there is sufficient magnetism created
by the shunt coil to pull down the armature, clos-
ing the contacts, automatically connecting the
generator to the battery. With the contacts thus
closed, the current in the series coil is flowing
from the generator to the battery or in the same
direction as the current in the shunt coil, so that
the pull on the armature is increased by mag-
netism of the series coil.
As the engine is stopping and the generator
loses speed, the voltage falls. As soon as the
generator voltage drops below the battery ter-
minal voltage, the current flows fram 'he battery
to the generator, reversing the direction of cur-
rent in the series coil so that the magnetism
created by the series coil is opposed to the mag-
netism created by the shunt coil, reducing the
magnetic pull on the armature and the spring
~pens the contacts, disconnecting the generator
f~om the battery. '
MAINTENANCE PROCEDURE
1. Contacts-The contacts can be cleaned by
filing, parallel with the length of the armature,
with a very fine file (ST-290 recommended) so
that they are free from pits or burning. After
filing the contacts should be cleaned with refined
carbon tetrachloride to remove any dirt or
grease. Pull a piece of clean linen tape between
the contacts to remove any residue.
2. Adjustments
a. Armature air gap .010 to .030 inches
This gap is measured with the contacts closed
 AUTO·LlTE
i:
I RELAYS AND REGULATORS - Continued
according to the temperature. The magnetic by-
pass is a small piete of nickel-iron across the top
af the magnet core. The magnetic conductivity of
this by-pass gradually increases as its temper-
.1 ature is reduced; Thus at low temperatures much
of the magnetic pull of the core which would norm-
ally affect the cutting in of the field resistance
flows thru this by-pass instead of the regulator
armature and results in a higher generator volt-
age being required to open the contacts and cut
in the field resistance. On the other hand at high
temperatures the magnetic conductivity of the by-
pllssis reduced thus allowing the magnetic pull
'. '~i'the core to have full effect on the regulator
-·Ormalure and.cut in the field resistance at a lower
u g~nerator voltage. (See Figures 45 and 46.)
TC regulators have an easily accessible
have the resistance controlling the gen-
. output mounted externally and a cover
which seals the working parts of the unit from
dust.
MAINTENANCE When testing TC regulators
PROCEDURE they should be removed from
the car and checked on the test bench where
temperatures are known and are fairly constant.
COLD
- =----=-=--
--.
1.1
PART OF MAG~ETIC LII-.lES PASSING
THROUGH MAGNETIC BY - PASS
LESS PULL ON ARMATUR~
FIGURE 45
elECTRICAL EQUIPMENT r!
Where it is necessary that the regulator be
checked on the car be sure that the car has stood
in a uniform temperature for at least 15 min-
utes. A thermometer, with its bulb placed near
the regulator, should be used whenever a check
of TC regulator action is made.
The voltmeter used to check IC regulator;
should be graduated in .1 volt readings. If the
test is made on the car a variable resistance
should be connected in series in the charging
circuit for proper control of the generator volt-
age.
1. Visual inspection
A visual inspection of the unit should be made
for:
a. Evidence of burning or abnormal high tem-
peratures at the coils, contacts, insulation,
external terminals or any other point .
b. loose connections resulting from poor sol-
dering.
c. loose nuts on the bottom of the magnet
cores, loose rivets or screws. All nuts and
screws must have lock washers.
2. Contacts
The contacts can be cleaned by filing, parallel
HOT
=
•
ALL OF MAGNETIC LINES PASSING
THROUGH ARMATURE NONE THROUGH
IvlAGNETIC BY-PASS MORE PULL ON ARMATURE
FIGURE 46
42
 AUTO-LITE ELECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

a

F
£

TERN. ;F" 0:''(>80# RESISTOR

FIGURE 47

with the length of the armature, with a very fine
file (5T-290 recommended) so that they are free
from pits ar burning. After filing the contacts
should be cleaned with refined carbon tetra-
chloride to remove any dirt or grease. Pull a
piece of clean linen tape between the contacts to
remove any residue.
3. Carbon Resistor
cording to the values given in the test specifica-
tions at the end of this section.
4. Circuit Breaker Unit
a. Armature Air Gap-.Q1 0 to .030 inches
This gap is measured with the contacts closed
and is adjusted by raising or I()wering the sta-
tionary contact "A' Figure 47.
b. Contact Gap-.015 to .045 ,"~rle•..

Check the resistance of the carbon resistor with Adjusted by bending the. armClture .
an 5T-284 ohmeter. The resistance must be ac- Figure 47.
POTENTIOM ETER
3AMP 100 OHM

VOLTMETER
TERM. "A"
TERM. "F"

I
I
I
!
TERMINAL

LIGHT
CP 6-8V

FIGURE 40
 AUTO-LITE E1ECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

5. TC Regulator Unit spdng by bending the lower spring holder "F"
,
,
'
a. Armature Air Ga~!>45 ± .001 in'i:hes Figure 47.
I
This gap is measured with the regulator or con- 2. TC Regulator Operation
tacts closed. It can be adjusted by raising or low- Connect a voltmeter as shown in Figure 49.
ering the upper contact "C" by expanding O"r' Increase the voltage from zero and note the volt-
contracting the bridge "D" holding the upper"' ""'age at which the contacts open as indicated by
contact. the lamp dimming or going out., This voltage
b. Contact,Gap-.005 inch minimum. figure should be within the test specifications for
Adjust by turning the brass cam "E" Figure 47. the unit being tested and at the temperature
TESTING A~ ADJUSTING shown. Adjust by varying the tension of spring
1. Circ!!,jf Breaker Operation "G" Figure 47 by bending the spring hanger "H".
, ,
Conne~t CI.Yoltmeter as shown in Figure 48. In- Reduce the voltage and check the contact
" cr!,ase t~~volfagefromzero and note the volt~, closing voltage as indicated by the lamp light-
at which ,the contacts by ing. This voltage should be within thE;;test spec,l-
This fications shown. Adjust by turning th;ibra~$rn'
;l~;",~ :':~P"_ - '_?~';I!_,."
specifi~a: "E" Figare 47.lO\I'his changes the contact" gap
~~~~~,oJj;']'.Jdlust by increas- which must not be less thqn .005 inch after
adlfents are completed.

TMETER

6V BATTERy'-.... _-----..j
FIGURE 49
 -"-.

AUTO·LlTE ELECTRICAL EQUIPMENT

RELAYS AND REGULATQRS - Continued

TC REGULATOR NUMERICAL INDEX
Part No.
Rated
Yolts
Test
No. Resistor*
'~.Fuse Port No.
Rated
Volts
Test
No. Resistor* Fuse
TC-4301A 6 1 1.4 5 TC-4310A 12 2 2.85 5
TC·4301B 6 1 1.4 5 TC-4310B 12 2 1.85 5
TC-4302A 6 1. 1.85. S TC-4311A 6 1 1.85 5
TC~4302B 6 1 1.1 5 TC-4312A 6 1 1.85 5
TC-4303A 12 2 2.85 5 TC-'I313A 6 1 1.85 5
TC-4303B 12 2 2.85 5 TC-4314A 6 1 1.85 7.5
TC-4303C 12 2 1.85 5 TC-4315A 12 2 2.85 7.5
TC-4303D 12 3 -..lJ,.-. 5 TC-4316A 6 1 1.85 5
TC-4304A 6 4 1.85 5 TC-4317A 6 1 1.85 5
TC-4~.Q5.A 6 1 1.85 ~ TC-4318A 12 2 1.85 5
T043i1lS8 6 5 1.85 5 TC-4320A 6 1 1.1 7.5
TC-43~ 6 6 1.85 5 TC-4320B 6 1 1.85 7.5
TC-4a··~· ~- 6 6 5.5 5 TC-4321A 12 2 2.85 5
TC-430SE 6 6 2.85 5 TC-4322At 12 2 1.85 5
TC-4305F 6 1 1.85 5 TC-4323A 6 7 20 5
TC-4306A 6 1 1.85 5 TC-4323B 6 7 7. 5
TC-4307Af 6 4 1.85 5 TC-4324A 6 6 2.85 5
-).
TC-430SAf 6 1 I.S5 5 *Ohmic re5istanc~ is the marked volue with a toterance of ± 5%.
TC-4309Af 6 1 1.85 5 tNo circuit breaker.

TC REGULATOR TEST DATA

TEST
CIRCUIT BREAKER 1 2 3
Resistance 'of Voltage Winding ... . 35-39 111-123 111-12~
Armature Air Gap ....................... . .. 010"-.030" . .010":,".030" .01 0"-.030"
Contact Point Gap ....................... . .015"-.045" .015"-.045" .0 15"~.045"
Point Closing Volts .................... ~•. 6.5-7.25 13.0-14.5 13.0-13.5
Point Opening Amps. Discharge .. .p-2.5 .5·2.0 .5-2.0
VOLTAGE. REGULATOR
Resisl!Jl1~e of Winding ................. . 29-33 102-112 102-'112"
ArmatWe Air Gap ........................ . .044" ~.046" .044" -.046" .044"-.046"
.. Contact' Point Gap ...................... ::· . .005" min . .005" min . .OQ5" min •
. High to Low Charge ................... .
. 50°F. .. ........... . S.65 17.30 15.95
60°F .......................... . a~.si" 17.12 IS.S0
70°F ........................... . S:50 17.00 15.65
SO°F :.. ..................... . 8.43 16.86" 15.50
90°F ............................. . 8.35 16.70 15.35
100°F. ................., ............. . 8.28 16.56 15.20
110°F ....................... . 8.21 16.42 15.05
Tolerance ...................... . ±.25 ± .40 ± .20 ± .25
Low to High Charge ................... . 1.2 to 1.4 2.4 to 2.8 2.0 to 2.4 '1.2'101.4
Volts below high to low Volts below high to low Vol~ below high to low, VoltS~below'hI9h to low
TEST
ORCUIT BREAKER 5 6
Resistance of Voltage Winding ....................... ;~:.: ......... . 35-39' :' 35-39
Armature Air ~p ........ ;~............................................... . .010"-.030" .,.010"-.030"
Contact Point Gap .................. ;',..................................... . .015"-.045" .015"-.0,45"
Point Volts... ..• . ........................ .' ..... . 6.4-7.0 6.4-7.0.
':, 1.0-3.5 1.0-3.5
,
29-33 29-33
.034~'-.03S". .044"-.046" .047"-.049"
.005':( min .., .005" min. .OO5'~ min •

S.IS 8.15 7.34

8.07 S.07 7119
e·OO 8.00 7 ..25
?/?3· 7.93 7111
·'7:i~5 7.85 7.16
..................................., ... '.;, ........ ,. '7.78 7.78 7.12
..................................... "'~"""'"'''' . . . )',71 7.71 7.08
. . ::.. ,,.~/{'~?;~th Chqrge" ........••••••••••••••••............................ .± .25
f.8'to 2.0
± .25
1.8 to 2.0
± .15
1.0 Ie, .1.2
below high to low Volts below high to low Volts ):Ielow
 AUTO-LITE ELECTRICAL
RELAYS AND REGULATORS - Continued
"~ VRB, VRD, VRE, VRF, VRJ, VRK, VRO, VRP, VRR, VRS, VRT, VRU, VRV, VRW and VRX
REGULATORS
DESCRIPTION While there are several types
AND FUNCTION of VR regulators they all op-
erate on the same general principle. The follow-
ing description of their construction and oper-
ation is given so that in making the tests as out-
lined they may be made more intelligently.
The VR regulators used with third brush con-
trolled generators have two units and two func-
tions to perform, namely, the closing and opening
of the circuit between the generator and battery
by means of the circuit breaker and the holding
of the voltage at a predetermined value by
.. /lleans of the voltage regulator unit. The current
limited by the conventional third brush action.
The. VR regulators used with shunt generators
three units, each performing a distinct and
'i~cle~,endent function; 1st, the circuit breaker to
and open the circuit between the generator
and battery; 2nd, the voltage regulator to hold
. #' -
thi~ystem voltage at a predetermined value;
and 3rd, the current limiting regulator to control
the maximum ampere output of the generator.
CIRCUIT BREAKER UNIT
The operation and function of the circuit
breaker unit is the same as described on page
40.
VOLTAGE REGULATOR UNIT
The electromagnet ,?f the voltage regulator
unit has a single winding which is shunt con-
nected directly across the battery charging cir-
·cuit. This connection is made at the circuit breaker
. . in order that the battery rather than generator
voltage win control its operation. When the vOlt-
age rises to a predetermined value, this winding
is energized sufficiently to cause the voltage regu-
.Iator contacts to open, thus cutting in a resistance
c 46
EQUIPMENT
in the generator field circuit wnich reduces the
generator voltage. Immediately upon the drop-
ping of the voltage the contacts close, shorting
out the resistance, and the voltage rises again
thus completing one cyde of operation. These
cycles occur at frequencies necessary to maintain
the voltage at correct vaiues as long as the volt-
age is high enough to keep the voltage regulator
unit in operation. With the addition of a current
load great enough to lower the battery voltage
below the operating voltage of the voltage regu-
lator, the contacts will remain closed and the gen-
erator will maintain its maximum charging rate .
The voltage regulator is compensated for tem-
perature variations through the use of a nickel-
iron magnetic by-pass whereby a higher voltage
is required to vibrate the contacts under cold
operating conditions than is required under hot
operating conditions. This is necessary as it re-
quires a higher voltage to charge a battery when
it is cold than when it is hot.
CURRENT LIMITING REGULATOR UNIT
The current limiting regulator unit used with
shunt type generators has an electromagnet with
a winding of heavy wire which is connected in
series between the generator "A" terminal and
the series winding of the circuit breaker, so that
the entire output of the generator flows through
it. When the generator output reaches its pre-
determined maximum (the ampere rating of the
generator with which the regulator was designed
to operate), the regulator contacts are opened,
inserting a resistance in the field circuit which
reduces the ampere output of the generator. Im-
mediately upon the dropping of the output the
contacts dose, shorting out the resistance and the
 AUTO-LITE ELECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

output rises completing one cycle of operation.
These cycles occur at sufficiently high frequency
so that the output is limited to a predetermined
maximum.
CAR TEST
NOTE-BEFORE ANY WORK IS DONE ON THE
REGULATOR THE FOLLOWING CONDI-
TIONS SHOULD BE CAREFULLY CHECKED
AND CORRECTED IF AT FAULT:-
1. WIRING FROM GENERATOR TO REGU-
LATOR PROPERLY CONNECTED.
2. HIGH RESISTANCE CONNECTIONS IN
THE CHARGING CIRCUIT. THIS SHOULD
BE CHECKED WITH AN ACCURATE READ-
ING VOLTMETER AND INSPECTED ME-
CHANICALLY FOR POORLY SOLDERED
TERMINALS AND LOOSE OR CORRODED
CONNECTIONS.
3. GENERATOR PERFORMANCE WITHOUT
THE REGULATOR IN THE CIRCUIT OPER-
ATING ACCORDING TO SPECIFICA-
TIONS.
4. THAT THE REGULATOR IS THE ONE DE-
. SIGNED FOR THE GENERATOR WITH
WHICH IT IS OPERATING. THESE REGU-
LATORS WILL FUNCTION SATISFACTOR-
ILY ONLY WHEN INSTALLED WITH THE
OPEN CIRCUIT TERMINAL VOLTAGE OF
THE BATTERY AS WEll AS ITS SPECIFIC
GRAVITY SHOULD BE CHECKED. THE
CONDITION OF THE BATTERY AS TO
CAPACITY, LEAKAGE, ETC. SHOULD BE
CHECKED BY SEPARATE TEST AS SPECI-
FIED BY THE BATTERY MANUFACTURER.
The equipment needed for testing on the car
includes an accurate indicating ammeter gradu-
ated in 1 ampere readings with heavy short
leads, an accurate indicating voltmeter gradu-
ated in .1 volt readings and a reliable ther-
mometer.
The resistance of the test ammeter must not
exceed .1 volts at 10 amperes or.01 ohms.lnstru- ..
ments which have resistance higher than this will
make it impossible to check or adjust the
with the necessary accuracy.
The drop in voltage from the regulator to
battery or from the generator to the regulatot
must not exceed .1 volt when the generator is
charging 10 amperes. At this same charging
rate the voltmeter should not show a reading
when measured from the regulator base to the
battery ground post, the generator frame to the
regulator base or from the generator frame to
the battery groun d post. (,
r: !/ /5'-.

GENERATOR DESIGNED TO OPERATE IT. •

l .- jl'
. [Iii •
0

,,~
~'
ALSO BATTERY CONDITION AFFECTS
REGULATOR OPERATION. AN OLD BAT- • [ ,<= J @
I~
• )
TERY, ONE PARTIALLY CHARGED OR "1I'loh@ "-2./
..;;:~F"'~
ONE SUBJECTED TO EXCESSIVE HEAT 15 Tr;1io
-~ Jill
WILL CAUSE HIGH CHARGING RATE;
WHILE ONE SUBJECTED TO EXCESSIVE =
COLD, HARD PLATES, HIGH RESISTANCE
SEPARATORS AND SULPHATION WILL
CAUSE LOW CHARGING RATE. THE
~F eATTUY

I
FIGURE 50
- "'" U
.~

47
 AUTO-LITE elECTRICAL
RELAYS AND REGULATORS -
~ Connections: Disconnect the wire from the reg-
Aator "B" terminal. Connect one ammeter lead to
the regulator "B" terminal and the other am-
meter lead to the lead removed from this terminal
as shown in Figure 50. One voltmeter lead should
be connected to the regulator "B" terminal on the
regulator side of the ammeter connection, while
the other voltmetEir lead is to be connected to the
terminal marked "GO" or to the,.base of the regu-
lator.·{lf the connections are not. made in this
manrier, false readings will be oflltained due to
. .,~
. voltage loss in the current connect,'!,,,s.}
·fhe thermameter should be placed,.sa· that its
bulb Is approximately two inches from the side af
"the regulator. It must not touch the regulator.
Battery: This mU,st read 1.275 ta 1.280 specific
gfCl,vity,lf the car battery is discharged, substitute
. .tel1lPorarily for test purposes a fully charged bat-
tery .in good condition of the same type and
'" ·capacity.
Test: Start the engine and set the throttle for
f::
a speed equivalent to approximately 30 M.P.H.
Run the engine for not leu than 15 minutes with
the car hood up before taking meter readings.
. With a generator charge of 10 amperes the volt-
meter should show a re"ding according to the
specification figures given for the regulator under
test at the temperature shown by the thermam-
eter. With readings according to these figures,
the voltage regulator unit can be passed as func-
tioning correctly. See pages 65 to 70 for com-
plete test data.
To test the current limiting regulator, the same
connections as notet above are used. Add an
.,electricalload ,pf a current value in excess of the
amperes noted on the name plate of the regu-
lator at a paint between the car ammeter and the
48
EQUIPMENT
Continued
battery. (This load may consist of a bank of
standard head light bulbs or a carbon pile rhea-
stat.) If the current limiting regulator is function-
ing correctly, the test ammeter will show a read-
ing of the maximum amperes shown on the name
plate of the regulator with an allowed variation
of ± 5%.
If the unit does not operate according to speci-
flcations it should be removed from the car and
. thoroughly checked and adjusted.
MAINTENANCE PROCEDURE
VISUAL INSPECTION
Before making any tests or adjustments it is
recommended that a close visual inspectian be
given the regulator, with special emphasis being
paid to the following points:
1. Broken regulator seal.
2. Evidence of burning or abnormal high
temperature at the coils, contacts, insula-
tion, external' terminals or ,.any other
point. (It is suggested that fhis test be
made with a magnifying glass.)
3. Loose connections which result from poor
soldering.
4. Loose nuts on the bottom of the magnet
cores, loose rivets or screws. 'All nuts and
screws must have lock washen.
5. Loose contacts.
6. Misalignment of contacts.
7.' Bent armature either at the./~ontact or
hinge end. (The armature should be per-
fectly straight from one end ta fhe other.)
8. Magnet yoke bent.
9. Bent armature hinges.
10. Reversed bimetal hinges an the circuit
 AUTO-LITE ELECTRiCAL EQUIPMENT

RELAYS AND REGULATORS - Continued

breaker unit. (When correctly installed rachloride to remove any dirt or grease. Pull a
the brass side must be up.) clean piece of linen tape between the contacts to
II. Stripped or crossed threads on any screw remove any residue.
or nut.
CARBON RESISTORS
12. Corrosion due to salt or acids.
I. Check the resistance of the carbon resis-
13. Broken ground straps.
tors. They should be removed from the regulator
14. Evidence of water having been inside of
and checked with ST-284 ohmeter. See Figure
cover.
51.
15. Incorrect, bent or distorted armature
On those regulators having more than one
spring. In case of doubt it is recommended
resistor it is extremely important that they be re-
that the spring be replaced.
placed in their proper position.
16. Broken or altered carbon resistors.
,.(.
17. Broken gaskets.
18. Incorrect wiring connections between
units.
See pages 65 to 70 for complete test data on
VR type r.agulatars.
'0 Q ,0,"" " .
CONTACTS
The contacts should be cleaned by filing, paral- o
lel with the length of the armature, with a very
fine file (ST-290 recommended) so that they are
free from pits or burning. After filing the con-
tacts should be cleaned with refined carbon tet-
FIGURE 52

CIRCUIT BREAKER UNIT

2. Check resistance of circuit breaker voltage
Winding.
An accurate reading ohmeter (ST-284) is
needed for this test and is made by disconnecting
the voltage regulator lead from the circuit break-
er yoke and measuring from thl! "A" terminal to
a ground on the base. Connections are shown in
Figure 52.
3. Check the armature 'air gap with the con-
tacts open.
FIGURE 51 "Use flat gauge (ST-281-3) .034" to .038" be-
,49.,
 AUTO-LITE ELECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

it does not rub against the side of the armature.
On early production regulators the armature
stop was at the end of the armature as shown in
Figure 55. To adjust bend this stop "B" being sure
that it does not rub against the end of the arma-

rlil l " 'I ,

FIGURE 53

tween the magnet core and the armature as close

to the hinge as possible as shown in Figure 53 ..

FIGURE S6

ture. Other early regulators had the armature

stop in the center as is shown in Figure 56. On
this type bend the stop "C" being sure it does not.
e rub against the side of the slot.

FIGURE 54

. Adjustment of the air gap is made by bending

c
•.. the armature stop "A" Figure 54 making sure that

FIGURE fil

On those applications where an indicating

lamp is used instead of an ammeter the regulator
circuit breaker unit has·a second set of contacts.
To adjust the armature air gap on this type af
unit bend the upper contact bracket "C" Figure
FIGURE 5S. 57 as required. BE SURE THAT THE BRACKET
50
 AUTO·L1TE
RELAYS AND REGULATORS -
SUPPORTING THE UPPER CONTACT DOES NOT
RUB AGAINST THE SIDE OF THE ARMATURE OR
TOUCH THE YOKE AND THAT THE CONTACTS
ARE ALIGNED.
FIGURE 58
4. Check the gap of the contacts
when open. See Figure 58.
This gap should be .015" mini·
mum, but will possibly be more than
this in actual adjustment.
Adjust by expanding or contract.
ing the bridge supporting the sta·
tionary contact, being sure that the
FIGURE 59
ELECTRICAL EQUIPMENT
Continued
contacts are perfectly aligned. This adjustment is
shown in Figure 59.
VOLTAGE REGULATOR
5. Check the resistance of the winding.
An accurate reading ohmeter (ST·284) is
needed for this test. To test measure from the lead
disconnected from the circuit breaker yoke to
ground. See Figure 60 for these connections.
6. Check and see that the spring upon which
the movable contact is mounted is straight and
that it is approximately parallel with the arma·
ture.
FIGURE 60
7. Check armature air gap.
FIGURE 61
Test with pin gauge. This is to be measured on
the .contact side as shown in Figure 61 apd .nel!f ..
 AUTO-LITE ElECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

spring are down in the holding grooves and that
the lower spring bracket is not distorted so that
the spring is not vertical.

CURRENT LIMITING REGULATOR UNIT

B. Check and see that the spring upon which
the movable contact is mounted is straight and

FIGURE 62

to the armature stop pin aBhown in Figure 62.

To test connect a 3 C.P. test light as shown in
Figure 63 in series with the "F" terminal, the
regulator base and a battery. With the low limit
pin. gauge in place depress the armature and
the light sh~uld go out or dim. With the high
limit gauge in place the light should stay lighted
wilE'" 'the armature is depressed. Use two fingers
(see Figure 64) to depress the armature being
careful not to touch the contact spring.
FIGURE 64
3 c.P.
LAMP
o. that it is approximately parallel with the. arm-
ature.
Re-install the spiral spring, being sure that the
correct spring is used and that both ends of the
BATTERY
spring are down in the holding grooves, and that
the lower spring bracket is not distorted so that
·0 FIG.42

FIGURE 63

To adjust slightly loosen the screw holding the

upper contact bracket and using ST-2B2 to raise
the bracket (see Figure 65) and tapping the top
of the bracket to lower tbe contact. Keep the con-
tacts in perfect alignment when adjusting.
Be sure that the screws are tightened with suit-
able lock washersand..,.e;.check the gap after
tightening the bracket screws.
~E!-install the spiral spring, being sure that the
correct spring is used and that both ends of the fiGURE 65

52.
 AUTO-LITE ELECTRICAL
RELAYS AND REGULATORS - Continued
the spring is not vertical.
9. Check armature air gap.
Test with pin gauge. This is to be measured on
the contact side as shown in Figure 61 and next
to the armature stop pin as shown in Figure 62.
To test connect a test light as shown in Figure
63 in series with the "F" terminal, the regulator
base and a battery. With the low limit pin gauge
in place depress the armature and the light
should go out or dim. With the high limit gauge in
place the light should stay lighted when the arm-
ature is depressed. Use two fingers (see Figure
64) to depress the armature being careful not to
touch the contact spring.
To adjust slightly loosen the screw holding the
upper contact bracket and using ST-282 to raise
the bracket (see Figure 65) and tapping the top
of the bracket to lower the contact. Keep the con-
tacts in perfect alignment when adjusting.
Be sure that the screws are tightened with suit-
able lock washers and re-check the gap after
tightening the bracket screws.
10. Check the contact gap with the armature
against the stop< pin. (See Figure 66)
Hold the armature down with two fingers being
FIGURE 66
53
EQUIPMENT
careful not to apply pressure to the spring sup-
porting the lower contact.
The test figures are approximate only; too
much variation indicates wrong length to the
armature stop pin and a new unit will be needed.
RE-ASSEMBlING THE REGULATOR
When all preceding checks and adjustments
have been completed, all the leads which have
been disconnected either by the removal of a
screw or by unsoldering should be re~connected.
Where resoldering is necessary care must be
taken that a good cleon contact is made. Do not
use acid for soldering flux.
After the regulator has been completely re-
assembled, its bottom should bestfllck sharply
on the bench several times to be sure thar~lrparts«
are settled in place. Then re-check <all adjust-
ments.
TESTING AND
LATOR WHEN TAKING
WHEN THE UNIT IS BEING HEATED BY OPER.
ATiON PRIOR TO TAKING READINGS. THIS
IS NECESSARY DUE TO THE FACT THAT THE
COVER FORMS PART OF THE MAGNETIC
FIELD AND ALSO HELPS TO RETAIN THE
HEAT.
When testing or adjusting< regulators, care ,
must be token that it is mounted firmly ahd in a
place where there is no vibration. It must also be
tested in the same position as it is mounted on the
car.
Care must be taken in making the various
test connections that these connections are firmly
made so that the resistance of all connections
does not exceed .01 ohms. <
 AUTO-LITE ELECTRICAL EQUIPMENT

RelAYS AND REGULATORS - Continued

HEAT THE REGULATOR BY OPERATING IT
FOR 15 MINUTES WITH THE GENERATOR
CHARGING 10 AMPERES. WHILE HEATING
HAVE THE COVER ON THE UNIT.
1. Check circuit breaker operation. )1
First Method-For circuit breakers having the
upper contact mounted on a spring.
When making this test the voltmeter is connec- I
ted between the "A" terminal of the regulator and
a ground on the regulator base. See Figure 67.
To obtain the settings increase the voltage FIGURE 68

until the contacts close but the armature does not
seal to the yoke. Take the contact closing voltage
at. this stage. Without increasing the voltage be-
yond thatcrequired to close the contacts decrease
. the voltage until the contacts open.
: Second Method-For circuit breakers with the
upper contact mounted directly on the arm-
ature.
To test, connect an ammeter in series between
the battery and the "B" terminal. The voltmeter
is connected to the "A" terminal of the regulator
and to ground. Be sure that the voltmeter con-
nections are on the regulator side of the ammeter
connections to avoid loses due to poor connec-
tions. See Figure 67. When testing increase the
voltage slowly noting the voltmeter reading just
before the contacts close. Increase the charging
rate to 15 amperes then reduce the charging.
rate noting the amperage discharge just before
the contacts open.
ADJUSTMENTS
To adjust the closing voltage adjust the arma-

~IL

;==
IT(~ -
A
•ill ><rom ] [,'Q.
,
~
GO.

t< -"'' ' jl

-··-IOl-:,..
~...
~.~;. ~'.
('5
e

'" r(
~
@
8

~
31
i~~ff·'5~
....
Illl,r JI (if
HEADPHONE
))
I IL
fr+
'fr. "-

I~ ,0

I II ~
I~
- '
••
~
BATTERY . AO
I if
fiGURE 67

54
 AUrO-lITE ELECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

CIRCUIT BREAKER UNIT
LOWER SPRING BRACKET-
BEND DOWN TO INCREASE ='-~ LOWER SPRING BRACKET-
CLOSING VOLTAGE-BEND BEND DOWN TO INCREASE
UP TO DECREASE
CLOSING VOLTAGE. UP TO DECREASE
VOLTAGE SETTING.

CURRENT LIMITING
REGULATOR UNIT
LOWER SPRING

TO INCREASE CURRENT SETTING;:::-~;;;;"_

BEND UP TO DECREASE CURRENT SETTING.
FIGURE 69

ture spring tension by bending the lower spring
bracket with ST-283 as shown in Figure 68. A
very accurate method of checking this closing
voltage is by connecting a headphone (2000
. ohms or higher) between the "S" terminal and the
"An terminal and taking the reading. just as the
click caused by the closing of the contacts is
heard. (See Figure 67, 69 and 70)
To adjust the opening voltage or amperage
adjust the contoct gap by raising or lowering the
stationary contact.
There must always be .5 volts less voltage at
which the circuit breaker closes than the voltage
at which the voltage regulator operates.
After each adjustment replace the regulator
cover and again test the circuit break~r actiCln
2. Check voltage regulator unit. ,
In making this test an accurate voltmeter must
be used. It is to be connected to the regulator"a"
terminal and to the regulator base as shown in
Figure 7l.
To adjust its operation, increase or decrease
the armature spring tension by bending the lower
spring arm with ST-283. (See Figures 69 and 70)
Replace the cover after each adjustment. Take
a flash reading by stopping the generator and , .
noting the moximum voltage reading when the
generator is re-started at approximately 10 am-
VOLTAGE REGULATOR UNIT
LOWER SPRING BRACKET-
BEND DOWN TO INCREASE
VOLTAGE SETTING -BEND

":~~,II
CIRCUIT BREAKER
" UNIT LOWER SPRING
BRACKET- BEND DOWN TO
INCREASE CLOSING- VOLTAGE-BEND
UP TO DECREASE .CLOSING VOLTAGE.
FIGURE 70

55
 AUTO-LITE ELECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

The ammeter should reod within 5% of the am-
, perage stamped on the nameplate of the regu-
"c:::J" @ lator.
~,
@
, If the amperage is outside the limits adjust the
current regulator unit by varying the spring ten-

I !3ATTEIi'Y
II
JI
IL
sion. This is done by bending the lower spring
bracket with ST-283. (See Figure 69) Replace the
cover after each adjustment and make a flash
test.

FIGURE 71
peres output with voltage regulator operating.
3. €heck current limiting regulator unit.
Connect the test ammeter in series between the
regulator "S" terminal and the battery.
,,' Increase,the load on the generator by placing
a lamp bank or other suitable resistance across
,f/le battery on the battery side of the ammeter.
POLARIZING
Generators should always be polarized before
running on car or bench. Do not polarize the
generator by holding the circuit breaker contacts
closed. Use a jumper from the starting switch bat-
tery connection to the "A" terminal of the gener-
ator. The excessive current in closing the circuit
breaker contact for this purpose may result in
burnt contacts.

VRA, VRC, VRG, VRH AND VRY REGULATORS

DESCRIPTION These regulators are of the MAINTENANCE PROCEDURE

AND FUNCTION heavy duty type. The De-
scription' and Functian and Car Test found on
pages 46 to 48 of this section is equally applic-
able to the heavy duty type regulatars. The main
difference is the size and the fact that on same of
,,
the heavy duty regulators a second winding is
used on the current limiting regulator. This sec-
ond winding is connected in series with the gen-
erator field circuit and is cannected so that the
rise and fall of the field current accelerates the
action of the curreiit'regulator armature. This
causes the cycles of aperation to occur at suffi-
ciently high frequencies to limit the output ta
minimum fluctu(1ti()~,
56
VISUAL INSPECTION
Sefore making any tests or adjustments it is
recommended that a close visual inspection be
given the regulator, with special emphasis being
paid to the following paints:
1. Sroken regulatar seal.
2. Evidence of burning or abnormal high
temperature at the coils, contacts, insula-
tion, external terminals or any other
point; (It is suggested that this test 'be ,
made with a magnifying glass.)
3. Loose connections which result from poor
soldering.
 AUTO·L1TE ELECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

4. loose nuts on the bottom of the magnet . should be cleaned with refined carbon tetra·
cores, loose rivets or screws. All nuts and chloride to remove any dirt or greose. Pull a
screws must have lock washers. clean piece of linen tape between the contacts to
5. Loose contacts. remove any residue.
6. Misalignment of contacts. CARBON RESISTORS
7. Bent armature either at the contact or
Check the resistance of the carbon resistors.
hinge end. (The armature should be per· These resistors are found on the under side of the
fectly straight from one end to the other.) regulator base and should be removed and
8. Magnet yoke bent. checked one at a time in order to avoid any inter·
9. Bent armature hinges .. changing. Use an accurate ohmeter for checking
10. Reversed bimetal hinges on the circuit the resistance.
breaker unit. (When correctly installed
CIRCUIT BREAKER
the brass side must. be up.)
11. Stripped or crossed threads on any screw 1. Check resistance of circuit breaker voltage
• winding.
or nut.
An accurate ohmeter is needed for this test..
12. Corrosion due to salt or acids.
13. Evidence of water having been inside of This test is made by disconnecting the' voltage
winding ground connection and measuring from '
cover.
the lead to the stationary contact.
14. Incorrect, bent or distorted armature
2. Check the armature air gap with the con-
spring .In case of doubt it is recommended
tacts open.
that the spring be replaced.
Use flat gauge inserted on the c()ntact side of
15. Broken or altered carbon resistors.
the brass pin in the core as shown in Figure 72.
16. Broken gaskets.
17. Incorrect wiring connections between
units.
18. Shunt leads and terminal on circuit
breaker armature must be free and not
interfere with armature movement or
touch tension spring .

.See pages 65 to 70 for complete test data on

VR type regulators.

CONTACTS
The ~9I}t.acts should be cleo ned by filing, par·
allel with the length of the armature, with a very
fine file (ST.290 recommended) so that they are
free from pits or burning. After filing the contacts FIGURE 72

57
 AUTO-LITE ELECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

3. Check gap of the contacts.
This gap should be .015" minimum, but will
possibly be more than this in actual adjustment.
(See Figure 73)
Adjust by bending the supporting arms of the
stationary contacts, being sure that both sets of
contacts are in perfect alignment and that con-
tact is made on both sets of contacts at the same
time. Use a straight edge across the top of the
\\ \
contact brackets to check their alignment.

FIGURE 73

Adjust by raising or lowering the stop at the con-

tact end of the armature.

a
""
FIGURE 7S

VOLTAGE REGULATOR
4. Check the resistance of the winding.
An accu~ate ohmeter is needed for this test. To
test disconnect both I.eads from the base and
measure between the terminals as shown in Fig-
ure 74.
. 5. Check armature air gap with contacts just
breaking.
Test with 'pin gauge as shown in Figure 75.
This measurement is to be taken on the contact·
side and next to the brass armature stop pin as
FIGURE 74 illustrated in Figure 76.
58
 AUTO-LITE ELECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

FIGURE 76
To test connect a 3 c.P. light as shown in Fig-
ure 77 in series with the "A" and "F" terminals
and a battery. With the low limit pin gauge in
place, depress the armature and the light should
go out.
With the high limit pin gauge in place, depre.~
on either side of the contact spring, so that the
contact spring, is not touched. The pressure
should be applied near the center of the arm-
ature.
To adjust loosen the screws and raise or lower
the armature contact stop.
Be sure that these screws are tightened with
suitable lock washers.
Check and see that the spring upon which the.
movable contact is mounted is straight and thot 'it
is parallel with the armature.
6. Check contact gap with the armature
against the stop pin. Figure 78.

the armature and the light should stay lighted.

Use two fingers in depressing the armature, one

FIGURE 78
o
, "~"'"~.. Hold the armature down with two fingers as
1;;;;lte\;;;LV jlh,strated taking care th.ot the contact spring is
~~~:rt§~-~-~-~-§~
:;;- . ~=--~~~:~~~4
..., not touched •.
o 0 If the gap 'istpo small check to see that the
bridge car..yi~g 'he nickel-iron shu~t has been
pushed down .in assembly. If the bridge is not
pushed down the armature rivets will strike the
shunt and prevent the contacts from opening'
--,,_.'- sufficiently.
3 C.P.
BATTERY LAMP The test figures shown are approximate only;
too much variation indicates wrang ,length to
~'~~:b<_

FIGURE 77 armafure stop pin and a ney(unitWW be ne,!'dl!d•.

- ".' ~- -, - '
 AUTO-LITE ELECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

sure that the fibre bumper black is in place. See
Figure 80.

CURRENT LIMITING REGULATOR

8. Check the resistance of the frequency wind-
ing. An accurate ohmeter (ST-284) is needed far
this test.

FIGURE 79

;Chei:k the pressure of the contads.

" .
:r(;tesf,
'~'",..
disconnect the spiral spring from the
i clrmlclfjm! and remove the adjustable armature
cy,;C~tpIP' Using a spring scale as shown in Figure 79
holding the armature firm, take a reading
~s the contacts separate.
'. N,L'
When re-assembling the armature stop, be

FIGURE 81

To test, disconnect the lead from the current

regulator unit where it is connected to the resistor
through the sub base .between the current and
voltage regulators and measure from this lead to
the current regulator yoke. See Figure 81.
When re-assembling the armature stop, be
sure that the fibre bumper block is in place. See
Figure 80.
, 9. Check the pressure of the contads.
 AUTO-LITE ELECTRICAL
RELAYS AND REGULATORS -
To test, disconnect the spii'al spring from the
armature and remove the adjustable armature
stop. Using a spring scale as shown in Figure 79
and holding the armature firm, take a reading
just as the contacts separate.
When re-assembling the armature stop be sure
that the fibre bumper I;>lock is in place. See Figure
80.
10. Check armature air gap with the contacts
just breaking.
Test with pin gauge. This is to be measured on
the contact side of the brass armature stop pin as
shown in Figure 76.
To test connect a 3C.P. light in series with the
"A" and "F" terminals and a battery as illustrated
in Figure 77. With the low limit pin gauge in
place depress the armature and the light should
go out. With the high limit pin gauge in place the
light should stay lighted. Use two fingers in de-
pressing the armature, one on either side of the
contact spring, so that the contact spring is not
touched. The pressure should be applied near
the center of the armature.
To adjust loosen the screws and raise or lower
the armature stop.
Be sure these screws are tightened with suitable
lock washers.
The spring upon which the movable contact Is
mounted should be straight and parallel with
",the armature.
11. Check contact gap" with the armature
,:'
EQUIPMENT
Continued
length to armature stop pin and a new unit will
be needed.
RE-ASSEMBLING THE REGULATOR
When all the preceding checks and adjust-
ments have been completed, all the leads which
have been disconnected either by the removal of
a screw or by unsoldering should be reconnected.
Where resoldering is necessary, care must be
taken that a good clean contact is made. Do not
use acid for soldering flux.
After the regulator has been completely .. ;t
assembled, its bottom should be struck. sharply
on the bench several times to be sure that an
parts are settled in place. When doing this be sure ~
that it is struck squarely on all four mountinglug..,'
Re-check all adjustments.
TESTING AND ADJUSTING
'\ .. ,
NOTE:-THE COVER MUST BE ON THEREGU-
i ~
LATOR WHEN TAKING READINGS OR WI-lEN
THE UNIT IS BEING,HEATED BY OPIERA.T:{QII'I,
PRIOR TO TAKING READINGS. THIS IS
ESSARY DUE TO THE FACT THAT THE COVER
HELPS RETAIN THE HEAT.,
When testing or adjusting regulators, care"
must be taken that it is mounted firmly gnd in 'i"
place where there is no vibration. It must also be·
tested in the same position as it is mounted on the
car.
,Care must be taken in making the various tesf
connections that these connections are fjrtnl~
made so that the resistance of all
does not ~xceed .01 ohms with a
charge. It is for this rea~n that spring.
nections are no! recommended. Flexible cgbleis.
which have Rat spade type ter'mil,als nr,1> r....." ...
 AUTO-LITE ELECTRICAL
RELAYS AND REGULATORS - Continued
mended, as experience shows that these prevent
high resistance connections from entering into
the test circuit.
It is suggested that a single earphone (2000
ohms or higher) be attached to the "F" terminal
and ground and used for listening to the regu-
lator armature vibrations and so obtain an ac-
curate indication of the operation of the current
limiting and voltage regulator units.
the regulator by operating it for 15 min-
the ge~~rpfor charging 10 amperes.
\.vII.:I_ heating the regulator have the cover on the
1. Check circuit breaker operation.
, •' To test, connect the ammeter in series between
< ,#" ,~
~E! ,ba'lteiY and the "B" terminal. The voltmeter
~;~()nllected to the "A" terminal of the regulatar
ground. Be sure that the voltmeter con-
nectic)n! anion the regulator side of the ammeter
BATTERY
EQUIPMENT
connections to avoid losses due to poor connec-
tions. See Figure 82.
To adjust the contact closing voltage adjust the
armature spring tension by adjusting the screw
"An Figure 83 which holds the lower end of the
spring. A very accurate method of checking the
contact closing voltage is by connecting a head-
phone (2000 ohms or higher) between the "A"
and "S" terminals of the regulator as shown in
Figure S2 and observe the voltage at which the
click, caused by the closing of the contacts, is
heard.
To adjust the contact opening amperag~,
adjust the contact gap by raising or lowering the
stationary contacts.
'After each adjustment, replace the regulator
cover and again test the circuit breaker oper-
ation.
There should always be .5 volts less voltage at
 AUTO-LITE ELECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

VOLTAGE
REGULATOR

"
CIRCUIT
BREAKER
,
B A

CURRENT LIMITING
REGULATOR
FIGURE 83

BATTERY

FIGURE 84
 AUT 0 - LI TE E L E C T R I CAL
RELAYS AND REGULATO~S -
which the circuit breaker closes than the voltage
~,
at which the voltage regulator operates.
At the conclusion of thIs check it Is necessary
that a flnal·flash test be made.
2. Check voltage regulator unit.
In making this test an accurate voltmeter must
be used. It is to be connected to the regulator "B"
terminal and to ground. See Figure 84.
adjust Its operatIon, increase or decrease
lTnlatlure sprIng tensIon. Increasing the spring
si()l~jl'c,[I,ases the voltage at which the unit
'Tolpe"at1e, while decreasing the tension de-
!ts,lqpE!rol!ing voltage. This is done byad-
,screw'uB" Figure 83 which holds the
• • the cover after making each adjust-
a, flash voltage reading by stopping
EQ U I PM E NT
Continued
the generator and noting the maximum voltage
reading when the generator is re-started.
3. Check current limiting regulator unit.
Connect the test ammeter in series between the
regulator "B" terminal and the battery. See Fig-
ure 84.
By increasing the generator output with a lamp
bank O~ other suitable resistance connected
across the battery on the battery side of the am-
meter, the ampere output should be as noted on
the name plate of the regulator under test with
an allowable variation of ± 5%.
Its~~'ration is adjusted by varying the arm-
ature spring tension. This is done by turning the'
screw "C" Figure 83 which holds the' lower end
of the spring,
It is necessary that after all adjustments are
made, a final flash test be made on all three units.
 AUTO-LITE ELECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

NUMERICAL LIST OF VR TYPE REGULATORS
See page 68 for test specifications.
Rated Test Ground Carbon Resistors· Operating
Part No. Volts Spec. . Polarity Rl R2 R3 R4 Amperage
VRA-4101A 12 1 Positive 135. 15 .65 19·21
VRA·4102A 12 1 Positive 135 15 .65 39·41
VRA·4103A 12 2 Positive 135 15 .65 19·21
VRB·4002A 6 4t Positive 60 ...... 29·31
·VRB·4002C 6 4t Positive 60 24-26
VRB-4002D 4t Positive 60
VRB·4003A 4t Positive 30
VRB·4004A 4t p'ositive 60 11
VRB·4004B 4f Positive 30 7
VRB·4004C Positive 60

VRB·4006A 6 Positive
VRB·4007A 6 Negative
VRB"4007B 6 Negbtive
VRB·4008A 6 Positive
6
6 4t Positive
6 4 Positive
6 4 Positive
6 4 Positive
I
VRB.4010A 6 4 Positive 30
VRB:4011A 6 4 Negative 60
VRB-4011B 6" 4 • Negative 30
VRB-4012A 6 4
. VRB-4012A-l
VRB-4012B·l ;,'t' 6 4 Positive 38
VRCc4i·01A 6 5 Positive 80
6. 5 Positive BO
6 5 Positive 80
6 5 Positive BO
6 4t Positive 20
B 6 4t Positiyf;t 20
• VRD"4002A 6 4t Positive." 20
f
(
VRD-4002B 6 Positive 20
6 i
6 6t Positive 20
6.- 4t Negative 20
6 4t Positive 20
6 4 • 20

6 8 Positive 30
6 4t Positive 20
6 4 Positive 20
12 9 Positive 60
......
VRE·4001C 12 9 Positive 60
VRE-4002A 12 9 Positive 60
VRE·4002B 12 9 .:~' " 60
VRE-4002C • 12 9 60
12 P!)sitive '
VRE·40GSK"""-" 12 P'O~itive 60
VRE-4003A-l . 12 ,Po~itive 60
VRE-4004A . 12 ' ':P6s;'tive . 60 20
'r· •• ' ;p~'sitive
VRE-4005A 12 60
resistance is the
.serici)·,,",umber ",um~er 8R-OOQOOl 'set,!9
 AUTO.L1TE ELECTRICAL EQUIPM¥T
--o;;r.;:..

RELAYS AND REGULATORS - Continued

~ Part No.
Rated
Volts
Test
Spec.
Ground
Polarity ., .- Carbon Resistors·
.2 R3
Operating
Amperag.
VRF·4Q01A 12 9 Positiv;~ 30
.·VRF·4Q03A 12 9 Positive 30
.VRF·4004A 12 9 Positive 30
VRF·4005A 12 9 Positive 30
. VRF·4006A 12 9 Positive 30
VRF·4007A 12 Positive
lA 12 Positive 31·34
12 Positive 31·34
12 Negative 19·21
12 Positive

Negative 80 15 30 54-56
Jo.,I~g,Q,tiy~ 80 15 30 54·56
\Positl~e 60 11 ........ 39·41
. Negative 60 11 39·41

Positive 60 20 29·31
Positive 38 7 34-36
Positive 60 15§ 31·33
Positive 30 7 27·29
Positive 60
Positive 60 11 24-26
Positive 60 15§ 39-41
~Positive 3S 7 34·36
30 7 27·29

Positive... 60
Positive' - 38
Positive 38
Positive

'Positive
Positive: 60 15§
38 7
·38 7
7
38 7
38 7
60 15§
60 11

60 15
60 11
60 11
60 11
 AUTO·lITE ELECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

Rated Tes' Ground Carbon Reliston· Operating
Part No. Volts Spec. Polarity RI R2 R3 Amperas.&
VRP·4009B 6 12 Negative 30 7 27·29
VRP·4009C 6 12 Negative 60 15§ 3941
VRP·4009D 6 12 Negative 30 7 24-26
YRP.4010A 6 12 Positive 60 15 31·33
:VRP·41Q1A 6 12 Positive 30 21·23.
VRP.4102A 6 12 Positive 3Q, 21·23
VRP·4103A 6 12 Positive 60 11 19·21
VRP:4104A 6 12 Negative 60 11 19·21
_VRP.41048 6 12 Negative 60 30 19·21
VRP4105A 6 12 Positive 60 30 19·21
VRP'420 I A.I 6 Positive 38 7 34·36
.I 6 Positive 38 7
6 Positive 30
6 Positive 20
6

Positive
Negative

. Positive
Positive
Positive

Positive
Positive
... Po_s!tiv~
... AUTO-LITE ELECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

VR REGULATOR TEST SPECIFICATIONS

TEST
1 2 3 4
CIRCUIT BREAKER
Res. of Voltage Winding ...... 49.7 49.7 35-39 35-39
. Ar.mafure Air GapL .055"-.062" .055"-.062" _034"-_038" _034"-_038"
,Confact Point Gap ..................... .. .015" min. .015" min. _015" min_ _015" min _
Points Close (Volts) .. . 13.0-13.5 13.0-13.5 . 6.4-7.0 6.4-7.0
Points Open (Amps.) ................. . .5-4.0 .5-4.0 .5-3.0 .5-3.0
REGULATOR
15.7-i7.3
.040"-.042"
15.7-17.3
.040"·.042"
12.8-14.3
.0595"-.0625"
10.4-11.2
.0595"-.0625"
..
.010"- min. ,OlD" min. .010"-.020" .010"-.020"

14.51 14.31 7.68 7..51

14.48 14.28 7.66 7.48
14.45 , 14.25 .7.65 7;45
14.42 14.22 '. 7.63
14.39 14.19 7.62
14.36·· ,~- -
14.16 7.61
14.33 14.13 . " 7.60
14.30 14.10 . 7.59
±.15 . , ,,' .± .. 15 . ± .•15

.018 .\;,. .0111····· c_:;",

',iJI.' ······047".049"
,047"-.049" ',2."_::1\' • .0595"-.0625".
"'-;-'c.""'~"""-:,~·········· .010" min.'" .010" min. .01O'i..020"
.'
"~;!,!:t!

5 6 7
, -, '0'
15.8-17.4 35-39 35~39.
.055"-.062" .034"'-.038" .034"-.038'"
.015" min •.. •015" min • ~iJi5"- min,•
6.5-7.0 6.4-7.0 6;4-7.0'
.5-4.0 .5-3.0 .<.5,3.0 •
",

4.3'4;7 10..4-}1.2' . 12.8-1.,4.3 1.0.4,:)1.2

.040"-.042" . .0595",.l)625"· .0595"-.0625"•• " . "0,5?5"" 0625" .
..01 0"~iC)20",l.·:jjfO'(920"
-,,/ .010" min. .Q1 Qr~ :.()20'~
, . ., ....,'.;' . ,

7;51 . "7.63 .7.98

7:48 7.56 7.96
7.45 7.50 7.95
7;42 7.43 7 ..93
7.:},? ,7,37 7.92
, 7.36 7.30 7.91
7.33 7.24 . 7.89
7.30 7.17 " 7.§8 .
± ;15 .• 15 ± .15,
 :-'! '
AUTO-UTE
:" -
ELEC'YRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

TEST
9 10 11 12
CIRCUIT BREAKER
Res. of Voltage Winding ............. . 111-123 49.7 345 29.8-33.0
Armature Air Gap~ ..................... . .034"-.038" .060"-.065" .034"-.038" .031"-,034')
Contael Point G!lp ............ ,.......... . .015" min. .015" min. .015" min . .ots"· min.
Points Clo~e (Volts) ............. w.... .. 13.0-13.75 13.0-13.5 25.0-25.75 6.4-6.6
Points Open (Amps,). ............ , ..... . .5-3.0 .5-4.0 ,5-2.0 ."
Points Opeil(Volts)................ :.... .
VOLTAGE REGULATOR
Res. of Winding .. 45.B-49.6 . 15.7-17.3 191-209
Armature Air Gap ....................... . .0595"-.0625" .040"-.042" .0595"-.0625"
'Contael Point Gap ........ ,,; .. .010"-.020" .010'~ min. .010"-.020"
Operatinl! Voltage
".
:~:~~
'SO°F' ................................ . 14.59· 27.B4
60°F ..................... . 14.54 27,67
70°F .......................... . 14.50 "14.45 27.50
BO°F .......... :.•~ ........ . 14.46 14.42 27.33
14.42 14.39 27.16
14.37 •14.36 26.99' .
14.33 14.33
14.28 14.30
.± ;t5 ± ,15

.047"-.049"
.010" min.

14
.~ 29.6,33.0
..03J," ••034"
, .Oi5"min.
, 6.4.:6.6'
'j'~'lt~~;ts:6
\10.8-12.Q
.048"-.052"
.012" ",In;"

. 7'6~3:'.
'7:~~ ','
·7;43
-~f>
7;38 . '<.>{~c-c
7.31
• 7/}:4
7,11,
::1;'.15 .± .•15

.04a",-.OS2"t
..012" min'.
 AUTO-LITE ELECTRICAL EQUIPMENT

RELAYS AND REGULATORS - Continued

TEST 17
~, 18
.IRCUIT BREAKER
Res. of Voltage Winding ............................................................................ .. 15.8-17.4 49.7
Armature Air Gapt ......................................................................................... . .0595"-.0625" .060"...065"
Contact Point Gap ........................................................................................ . .015" min. .015" min.
Points Close (Volts) ........................................................................................ .. 6.5-6.6 13.0·13.5
Points Open (Amps.) ...................................................................................... .. 0.5·4.0 0.5--4.0
VOLTAGE REGULATOR
Res. of Winding ............................................................................................ .. 4.3-4.7 15.7-17.3
Armature Air Gap ......................................................................................... . .040"-.042" .0465"-.0495"
Contact Point Gap .......................................................................................... . .010" min. .010" min.
Operating Voltage
50°F ........................................................................................................ .. 7.41 14.31
60°F .............................................................................................. .. 7.38 14.28
70°F .. ............................................................................................... .. 7.35 14.25
~-,:

.-.' 80°F . ................................................................................................ .

90°F .........................................................................................................
7.32
7.29
14.22
14.19
100°F ......................................................................................................... . 7.26 14.16
.110°F ......................................................................................................... .. 7.23 14.13
"'120°F ........................................................................................................ .. 7.20 14.10
.Tolerance ................................................................................................... . ± .15 ± .15
;:,,+'KKt:NT REGULATOR
of ,Frequency Winding .............................................................................. .033-.037
,'rn,al'lII'8 Air Gap ......................................................................................... . .047"-.049" .0465"-.0495"
'Cc

Conlact Poinl Gap.......................................................................................... .. .010" min. .010" min. ,

70·
 AUTO-LITE ELECTRICAL EQUIPMENT

STARTING MOTORS AND SWITCHES

DESCRIPTION AND FUNCTiON
The starting motor is designed to crank the
engine when the starting switch closes the circuit
between the storage battery and the motor. The
design of the starting motor depends upon the
type and application of the engine on which it is
to be used. Starting motors vary as to size, num-
ber of poles and number of brushes.

MOTOR DRIVES FIGURE 87

To transmit power to the flywheel of the en- In either case the action of the clutch is identical.
gine Auto-lite starting motors use either an over- Figure 88 illustrates a typical overrunning ukoh,'
d,

running clutch or a Bendix drive. Some motors
have a gear reduction between the armature
and drive pin ian to increase the power for heavy
duty ,installations. (See Figure 85).
The clutch has internal splines to match the "
on the armature shaft. When the yoke '''''.",.•
shifted, either mechanicolly or eleicfr'icaIlY:'
JI' -:', -':-,
complete drive is moved along the armature shalt;'

FIGURE 85

The over~unning clutch pinion may be shifted
either mechanically through a starter pedal (Fig-
ure 86) or electrically by a solenoid (Figure 87).
until the pinion meshes with the flywheel ring
gear. If the pinion teeth do not mesh with the
flywheel teeth the movement of the yoke arm is
taken Up by the spring. When the switch contacts
close the armature rotates allOWing the spring tov

FIGURE 86 FIGIIIIE 88

71
 AUTO-LITE ELECTRICAL EQUIPMENT

STARTING MOTORS AND SWITCHES - Continued

complete the meshing action and crank the en-
,~

ne. As soon as the engine starts the flywheel

drives the pinion faster than the starting motor
armature bringing the clutch into action and pre-
venting the engine from driving the armature at
excessive speeds.
The Bendix drive is illustrated in Figure 89. It
FIGURE 90

and is mounted separate from the motor. It

has a set of contacts that are opened and closed
by mechanical action. The contacts are designed
for the large currents in a starting circuit. Spring
action is used to open the contacts to give a clean
break and to minimize arcing.
The second type of manual switch is shown in
Figure 91 and is remote controlled from the dash

FIGURE 89

consists of a threaded sleeve fastened to the ar-

mature shaft through a drive spring and a pinion
mounted on the threads of the sleeve. When the
~iarting circuit is closed the armature revolves
FIGURE 91

,,'
turning the sleeve within the pinion forcing the by a Bowden wire. This type is also used on start-
gear forward meshing it with the flywheel gear. ing motors using a Bendix drive.
The sudden shock of meshing is absorbed by the The third type such as shown in Figure 92 is
spring. When the engine starts the pinion is driv- mechanically closed by depressing the clutch
en faster than the sleeve and is forced bock along
the threads automatically de-meshing it from the
flywheel.
STARTING SWITCHES
Starting switches, which control the closing and
opening of the circuit between the storage bat-
tery and the motor, may be of either the manual
or solenoid type.
Manual type starting switches may be one of
four. types. The type illustrated in Figure 90 is
used with starting motors having a Bendix drive FIGURE 92

72
 AUTO-LITE ElECTRICAL EQUIPMENT

STARTING MOTORS AND SWITCHES - Continued

pedal and has a vacuum release and vacuum re-
lease lock to prevent operation of the starting
motor when the clutch pedal is depressed while
the engine is running. With the engine not run-
ning depressing the clutch pedal closes the start- \ TERt1,W"L pos 7

ig switch thru cam "A," latch "B" and pressure arm

"C." When the engine starts the latch "B" is lifted
thru a connection to the vacuum diaphragm
so that it disengages with the cam and the switch
is opened by spring action. As long as the engine
continues to run the latch is held in the disen- ~P"UN,C;ER SPRING

gaged position so that the clutch pedal can be

operated without closing the switch. --I'-1""Ne"TIC COIL.

The last type such as shown mounted on the

motor illustrated in Figure 86 is used only on FIGURE 93

motors with overrunning clutches. It is controlled

by a foot pedal that is connected by linkage to
the shift yoke which moves the clutch pinion into
mesh and then closes the switch contacts.
Solenoid starting switches may be divided into
two types: those which magnetically dose the
starting circuit and those which not only close the
starting circuit but also shift the overrunning
clutch pinion.
The first of these types is shown in Figure 93
and is used with Bendix drive motors. It magnet-
ically closes the circuit between the storage bat-
tery and the motor and is controlled by a push
button located on the instrument panel.
The second type not only magnetically closes
the starting circuit but it also shifts the overrun"
ning clutch pinion into mesh with the flywheel

TO
STARTER

~7;:::r::;~,"","J."t:=--' GROU~ID TO SWITCH COVER

FIGURE 94

73
 AUTO-LITE ELECTRICAL
STARTING MOTORS AND SWITCHES -
gear. It is controlled by a push button, mounted
,~
<l" the instrument panel, thru a relay mounted
within the switch. (See Figure 94).
The solenoid coil includes two windings; a
series winding connected from the relay station-
,
ary contact to the main switch terminal connect-
ing with the starter motor and a shunt winding
connected from the relay stationary contact to
ground. Between the time the relay contacts close
MAINTENANCE PROCEDURE
A periodic inspection should be made of the
starting circuit. While the interval between these
checks will vary accordng to the type of service
it should, under normal conditions, be made
every 5000 miles. At this check the following
points should be inspected.
1. Wiring
A visual inspection should be made of all wires
to be sure that none are broken and that all
connections are clean and tight.
2. Commutator
If the commutator is dirty or discolored it can
be cleaned with 00 sandpaper. Blow the sand
out of the motor after cleaning.
Should the commutator be ro'ugh or worn the
motor should be removed from the egine for
cleaning and reconditioning. Instructions for the
servicing of starting motors are given later in this
section.
3. Brushes
The brushes should slide or swing freely in
their holders and make-full contact on the com-
mutator. Worn brushes should be replaced.
4. Lubrication
Motors having oilers should have 5 to 10 drops
74
EQUIPMENT
Continued
and the main switch is closed both windings have
current flowing thru them causing the solenoid to
exert its strongest magnetic pull on the plunger
thus assuring positive meshing of the pinion.
When the main switch contacts close the series
winding is short circuited and the plunger is held
in place by the shunt winding only. This results in
a minimum amount of arcing at the relay contacts
when the switch opens.
of a good grade of S.A.E. No. 20 oil added each
5000 miles.
STARTING MOTOR OVERHAUL
At intervals of approximately 25,000 miles the
starting motor circuit should be thoroughly
checked and the motor removed from the car for
cleaning and checking.
1. Starting Circuit
The starting circuit should be inspected to be
sure all connections are clean and tight and that
the insulation on the wires is not worn or dam-
aged. The starting circuit should be given a
voltage loss test to make sure there is no loss of
starting motor efficiency due to high resistance
connections. (See Figure 95) In making this check
the voltage loss from the battery terminal to the
starting motor terminal should not exceed .12
volts maximum for each 100 amperes. The loss in
voltage between the battery ground post and the
starting motodrame should not exceed .12 volts
maximum for each 100 amperes. If the voltage
loss is greater than the above limits the voltage
should be measured over each part of the circuit
to locate the resistance causing voltage loss.
When measuring the voltage loss across solenoid
 AUTO-LITE
STARTING MOTORS AND SWITCHES - Continued
---------- -.,
STARTING
MOTOR
,...I-,.,_'Q. . .~ - - - -,
... IC-
--\:--
~
- +
BATTERY
switches the contacts should be closed electric-
ally to simulate actual conditions of operation.
DISASSEMBLY
To remove the starting motor from the car dis-
connect the leads and cover the battery lead
with a short piece of hose to prevent short cir-
cuiting. Take out the flange bolts holding the
motor to the flywheel housing. The motor will then
lift off and can be taken to the bench for a com-
plete overhaul.
When disassembling the motor each part
should be removed a!ld cleaned and inspected
for wear or damage. The Bendix drive or over-
running dutdHhould be cleaned and inspected
for wear and for a distorted spring. Bearings
should be checked for proper clearance and fit.
A" insulation should be free from oil and in good
ELECTRICAL EQUIPMENT
CONNECTIONS
2-RESISTANCE OF CABLE C0NNECTIONS
I - RESISTANCE OF GROUND CONNECTIONS
,i .
PI
I
I
500 AMPERE 1000 WATT
SHUNT CARBON PILE
FIGURE 9~
condition. The ormature, field coils and brushes
should be checked for grounds ·or open circ':;its.
2. Brushes
The brushes should slide or swing freely, in
their holders and make full contact on the com-
mutator. Worn brushes should be replaced.
When replacing brushes that have the lead
riveted to the brush holder the rivet should be
removed and the new rivet should be securely
staked to make sure the brush .holder is solid and
that the lead makes a good ground cantatt.
Brushes that are soldered to the field coil lead
should be unsoldered and have the loop in the
field coil lead opened. The new brush pigtail
should be inserted to its full depth in the loop and ..
then clinched before resoldering. A good solder"
ing job must be done to insure no loss of starting
motor efficiency due to a poor contact.
75
 AUTO-LITE ELECTRICAL EQUIPMENT

STARTING MOTORS AND SWITCHES - Continued

Brush spring tension should be checked with a use a set of test probes such as illustrated in Fig-
spring scale. See specifications on page 81. To ure 96.
check the tension on swinging type brushes hook
the scale under the brush screw tight against the
brush and exert the pull in a line parallel to the
side of the brush. Take the reading just as the T~ST POINTS

brush leaves the commutator. When checking the

tension of reaction ,type brush springs hook the
scale under the brush spring near the brush and
pull on a line parallel with the side of the brush.
FIGURE 96
Take the reading just as the spring leaves the
'0 test the armature for grounds touch one
brush.
point to a commutator segment and touch the
If the brush spring tension is too low there will
core or shaft with the other probe. Do not touch
be a loss of efficiency due to poor brush contact.
the points to the bearing surface or to the brush
If the tension is too great the commutator and
surface as the arc formed will b"rn the smooth
brushes will wear excessively and have short life.
fi~ish. If the lamp lights, the coil connected to the
It is therefore important that the. brush spring
commutator segment is grounded.
tension be kept within the limits specified. To
To test for shorted armature coils a growler is
change reaction type spring tension twist the
necessary. The armature is placed against the
spring holder with long nosed pliers. On swing-
ing type brush holders it is necessary to remove STEEL STRIP HELD ON
'me spring and arm, and bend the spring to
ARMATURE SLOT

change the tension.

3. Commutator
Check the commutator for wear or discolor-
ation. If the commutator is only slightly dirty or
discolored it can be cleaned with 00 ar 000
sandpaper. Blow the sand out of the motor after
cleaning the commutator. If the commutator is
rough or worn the armature should be removed
and the commutator turned down in a lathe.

4. Armature
The armature shovld·be visually inspected for
mechanical defects before being checked for
shorted or grounded coils.
For testing armature circuits it is advisable to
76
 AUTO-LITE ELECTRICAL
STARTING MOTORS AND SWITCHES - Continued
core and a steel strip held on the armature. The
armature is then rotated slowly by hand. If a
shorted coil is present the steel strip will become
magnetized and vibrate. This test is illustrated in
Figure 97.
5. Field Coils
Using the test probes illustrated in Figure 96
check the field coils for both opens and grounds.
To test for grounds place one probe on the motor
frame or pole piece and touch the other probe to
the field coil terminals. If a ground is present the
lamp will light.
Ta test for open circuits place the probes on
the field coil terminals across each coil separate-
ly. If the light does not light the coil is open
circuited.
6. Brush Holder Inspection
Using the test probes illustrated in Figure 96
touch the insulated brush holder with one probe
and a convenient ground on the C.E. plate with
the other probe. If the lamp lights it indicates a
grounded brush holder.
7. Assembly of Motor
When assembling absorbent bronze bearings
always use the proper arbor as these arbors are
designed to give the proper bearing fit. Soak
the bearing in oil before assembling in the bear-
ing bore.
The pinion end of the armature shaft should be
given a light wipe with very light oil when
assembling.
Brushes should be correctly installed and con-
nected as previously outlined in order to be sure
of proper~,sf<'rting motor efficiency. Proper brush
seating should be insured by sanding the brushes
to fit the commutator. To sand the brushes wrap
a strip of 00 sandpaper around the commutator
77
EQUIPMENT
and turn the armature slowly in the direction of
rotation. Blow the sand and carbon dust out of
the motor after sanding.
When installing the yoke and overrunning
clutch the yoke shoes should be assembled with
the radial side toward the pinion end of the
clutch.
8. lubrication
Auto-Lite starting motors are equipped with
absorbent bronze bearings. These bearings are
able to absorb 25% of their own volume in oil.
Most of the drive end and intermediate bear-
ings do not need any attention. The commutato~
end bearing and some of the intermediate bear-
ings are equipped with oilers which should be
given 5 to 10 drops of medium engine oil every
5000 miles. Do not over lubricate as excessive
lubrication will damage commutators and insu-
lation.
Gear reduction motors have a grease pocket
in the gear chamber which should be filled with
a high melting point grease when assembling. If
this gear reduction is provided with a grease cup
it should be given one turn every 5000 miles. If an
oiler is provided it should be given 5 to 10 drops
of medium engine oil every 5000 miles.
When the starting motor is serviced the bear-
ings should be soaked in oil and the bearing seats
should be given a light wipe of oil.
9. Bench Test
Tlie motor should first be checked to see that
the free running voltage and current are within
specifications. (See page 81 for test data.) To test
connect the motor to a battery and voltmeter
as in Figure 9B. If the current is too high check
the bearing alignment and end play to make
sure there is no binding or interference.
 AUTO-LITE ELECTRICAL EQUIPMENT

STARTING MOTORS AND SWITCHES - Continued

500 AMP. SHUNT

[

1000 WATT
CARBON
PILE
o

BATTERY

"'--vc,Ln.. TER CONNECTIONS

FIGURE 98

Using a spring scale and torque arm as shown
in Figure 99 check the stall torque to see that the
motor is producing its rated cranking power.
The stall torque will be the product of the spring
scale reading and the length of the arm in feet.
. If the torque is not up to specifications check the
seating of the brushes on the commutator and
the internal connection of the motor for high
resistance. (See page 81 for test data.)
The Bendix or clutch should be checked for cor-
rect operation. The Bendix pinion should be
checked to see that it shifts when the motor is
operated under no load. The overrunning clutch
should be inspected for proper clearance when
in the free running position. This clearance should
be 5164" ± 1164" between the outer edge of the
pinion and the thrust washer next to the outer
pinion housing bearing as shown in Figure 100.

500 AMP. SHUNT

1000 WATT
CA~80N
PILt
TORQUE
TEST
."
8ATTERY
50 POUNO
~~
~
SPRING SCALE X VOLTMETER CONNECTIONS
L -______~J PULL HERE

FIGURE 99

78
 AUTO-LITE ELECTRICAL
STARTING MOTORS AND SWITCHES -
To check this clearance shift the pinion by apply-
ing pressure to the yoke arm on the positive shift
type or by applying pressure to the plunger of the
solenoid switch on the magnetic gear shift type.
i PI.'IIO/V HOUSINt:i
FIGURE 100
To adjust the clearance, screw the starting switch
plunger in or out on the positive shift starting
motors or adjust the plunger screw on the mag-
netic shift starting motors.
STARTING SWITCH TESTS
MANUAL. SWITCHES
This type of switch can best be tested by com-
paring voltage readings between the terminal
connected to the battery and the terminal
connected to the starting motor. A maximum vari-
ation not in excess of .05 volts per 100 amperes
is allowed. A greater variation indicates poor
switch contacts. Switch contacts should be filed
for full surface contact or the complete switch
replaced.
55-4000 SERIES SWITCHES
This type switch should be checked to see that
the opening and closing voltages are within limits
and that the voltage loss across the main contacts
is not in excess of .05 volts per 100 amperes.
When checking this voltage loss have the con-
79
EQUIPMENT
Continued
tacts closed by ehergizing the switch to approxi-
mate the actual conditions of operation.
TEST SPECIFICATIONS
Amperes Draw
6 volt units--2.9 to 3.3 amperes at 6 volts.
12 volt units--1.47 to 1.57 amperes at 12 volts.
Switch Contacts Close
6 volt units-4 to 5 volts
12 volt units-8 volts maximum
Switch Contacts Open
6 volt units-.5 to 2.0 volts
12 volt units-1.5 to 4.0 volts
55-4100, 55-4200 and 55-4700 SWITCHES
The relay contacts when open should have .025
inch minimum to .035 inch maximum gap.
Before making any tests on the switch make'
sure that cilliinkage operates freely with no bind-
ing and that the switch plunger can be bottomed'
in the solenoid without drag or restriction. When
under test the plunger should bottom' instantly
without chattering.
TEST SPECIFICATIONS
55-4100-6 volt units
Relay
Contacts close 3.5 to 4.5 volts
Contacts open 1.5 to 2.5 volts
Solenoid
Shunt coil only 14 to 16 amperes at 6.0 volts
Shunt and series 34 to 38 amperes at 3.0 volts
55-4100-12 volt units
Relay
Contacts close 7.0 to 9.0 volts
Contact. open 3.0 to 5.0 volts
Solenoid
Shunt coil only 5.0 to 6.0 amperes at 12.0 volts
Shunt and series 22:0 to 26.0 amperes at 6.0 volts
 AUTO-LITE ELECTRICAL EQUIPMENT

STARTING MOTORS AND SWITCHES - Continued

55-4200-6 volt units 55-4700-6 volt units
~

Relay
Contacts close 3.5 to 4.5 volts
Contacts open 1.5 to 2.5 volts
Solenoid
Shunt coil only 7.0 to 8.0 amperes at 3.0 volts
Series coil only 27.0 to 30.0 amperes at 3.0 volts
Relay
Contacts close 3.5 to 4.5 volts
Contacts open 1.5 to 2.5 volts
Solenoid
Shunt coil only 7.0 to 8.0 amperes at 3.0 volts
Series coil only 38.0 to 42.0 amperes at 3.0 volts

55-4200--12 volt units

Relay
Contacts close 7.0 to 9.0 volts
Contacts open 3.0 to 5.0 volts
Solenoid
Shunt coil only 1.8 to 2.2 amperes at 5.0 volts
Series coil only 15.5 to 18.5 amperes at 5.0 volts

I
80
"', '
"'-,;.,.,
,- """
",::,:,~:...,<u,,,;-",,,,,, i."_,jo'~·"_,.,;,,,, '-;~"'"'_ .; ;,,, i ~ ~>"'>R/(''''
 AUTO-LITE ELECTRICAL EQUIPMENT

STARTING MOTORS AND SWITCHES - Continued

STARTING MOTOR TEST SPECIFICATIONS

Spring
Gear Tension No Load Stall Test
Type Volts Ratio Ounces Volts Amps. Min. RPM Volts Amps. Min. Ft. Lbs.

01 6 56-60 6.0 60 4500 3.6 730 29.2

01 12 56-60 6.0 410 16.6
ON 6 56-60 6.0 50 3000 3.6 810 39.0
OY 6 36-40 6.0 50 3000 3.5 720 29.4
MAB 6 42-53 5.5 60 3700 4.0 775 22.5'
MAO 6 42-53 5.5 60 3600 4.0 730 18.5
MAJ 6 42-53 5.5 67 4100 4.0 750 17.0
MAK 6 38-61 5.5 70 5000 4.0 520 7.0
MAL 6 42-53 5.5 50 3200 4.0 825 32.0
MAO 6 24-32 5.5 44 2700 4.0 975 48.5·
.
MAP 6 5.5 41 9000
MAR 12 11.0 45 10000
MAS 12 12-16 11.0 35 4100 6.0 440 20.0
MAU 12 42-53 11.0 65 4800 6.0 540 17.3
MAU 12 2:1 42-53 11.0 65 2500 6.0 535 35.0
MAW 6 42-53 5.5 65 4900 4.0 670 18.0"
MAX 6 42-53 5.5 65 5300 4.0 880 25.0
MAX 6 22:14 42-53 5.5 70 3900 4.0 845
MAX 6 29:14 42-53 5.5 77 2695 4.0 906
MAY 12 42-53 11.0 30 5300 6.0 285
MAY 12 29:14 42-53 11.0 42 2500 6.0 260
MBA 6 42-53 5.5 65 4500 4.0 700
MBB 6 5.5 60 10000
MBC 11 5.5 35 10000
MBO 24 40-50 22.0 70 5800 6.0 590 35
MBE 12 38-61 H.O 6200 6.0 300 3.&
M8E 12 2:1 38-61 11.0 3500 6.0 300 8.4
MBF 12 10.0 22 4800 5.0 135 6.0
MBG 12 42-53 11.0 55 7300 6.0 375 9.8
MBH 6 5.0 40 6000 4.0 500 12.0 .
MBJ 12 11.0 65 6400 6.0 570 18.0.
MBK 6 5.0 65 11000
MBl 6 5.5 60 5000 4.0 420 5.0
MBM 6 5.5 60 5000 4.0 420 5.0:.
Ml 6 12-16 5.5 50 2980 4.0 750 26.0· '.
Ml 12 12-16 5.5 50" 2980 4.0 750 26.0
MR 6 12-16 5.5 40 2800 4.0 700 43.0
MR 12 12-16 11.0 50 4300 4.0 700 43.0
MZ "6- 42-53 5.5 70 4300 4.0 560 n.s
MZ 12 42-53 11.0 . . 55 7300 6.0 375 9.S .
."
~"

81